Bio-diesel manufacture with a micro-reactor

ABSTRACT

Methods and apparatus for producing bio-diesel from triglycerides and lower alcohols, desirably in the presence of liquid or supercritical CO 2 , are provided. The apparatus are designed to enhance the miscibility of the triglycerides with lower alcohols.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.60/783,963, filed Mar. 20, 2006; U.S. Provisional Application No.60/786,959, filed Mar. 29, 2006; and U.S. Provisional Application No.60/799,515, filed May 11, 2006, the entire disclosures of which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the improved and efficient manufactureof renewable fuels and in particular, the production of normally liquid,fluid, renewable fuels and more specifically bio-diesel, from animal andplant fats or triglycerides by the method of trans-esterification. Theproduction methods disclosed may use high pressure in miniaturized ormicro and nano (when channels are below about 100 μm diameter) chemicalprocessing apparatus. The purpose of the apparatus is to reduce thefloor space needed to install the complete production system, whencompared with the typical bio-diesel processing plant used previouslyand/or to create conditions under which triglycerides and lower alcoholsmix efficiently.

BACKGROUND OF THE INVENTION

Hitherto, bio-diesel has been produced in ambient conditions byproviding a catalyst, such as sodium hydroxide or potassium hydroxide,blended with an excessive quantity of methanol and a quantity of refinedanimal or plant fat; most preferably the fat or triglycerides are heatedto about 120° F. then the combined liquids and catalyst are transferredto a storage vessel or reactor and agitated for up to approximately 7hours or more, until the animal fat (triglycerides) has reacted with asmuch methanol as the triglycerides have chemical bonds to allow and thereaction phase of bio-diesel production is complete. Bio-diesel producedin this way requires copious quantities of clean water to wash anydetergents, such as sodium stearate (otherwise known as soap) from thefluid bio-diesel that will likely be present in small quantities. Theexcess methanol and catalyst is then allowed to stratify after transferto a suitably, elongated, tall vessel, or separation column, where thebio-diesel (e.g., specific gravity=approximately 890 Kg/M³) can stratifyinto layers according to the specific gravity of each fluid present;therefore, the lowest stratified layer would be glycerol (specificgravity=1126 kg/M³) with water (specific gravity=approximately 1000Kg/M³) directly above the glycerol, bio-diesel fatty esters(approximately 890 Kg/M³) above the water and the surplus methanol(specific gravity=approximately 791.3 Kg/M³) floating above thebio-diesel. The stratified and separated fluids can then be de-canteredfor subsequent use as intended, with recycling of surplus methanol andthe bio-diesel for use as the intended liquid fuel.

SUMMARY OF THE INVENTION

One aspect of the present invention is directed to a process for theproduction of bio-diesel that uses liquid or fluid, dense phase CO₂ asan alternative or additional catalyst. The use of liquid or fluid, densephase CO₂ (L-CO₂) significant reaction time reduction and alsofacilitates a more complete reaction of triglycerides with a loweralcohol, such as methanol or ethanol, followed by an improved separationof firstly, clean bio-diesel and secondly, glycerol from the remainingfluid comprising excess methanol and/or ethanol, catalyst, L-CO₂ andimpurities. More specifically, the improved separation process comprisesan enclosed, pressurized, vertically disposed centrifuge using liquidCO₂ as a liquid medium for separation of crystallized bio-diesel andglycerol. The use of a pressurized centrifuge is described in patentapplications by the present inventor, for example, as in U.S. PatentApplication Publication No. 2005/0042346 and in International PatentApplication No. PCT/US2005/043507, filed Dec. 2, 2005, which waspublished on Jun. 8, 2006, under Publication No. WO 2006/060596. Theabove patents and the disclosures of all patent applications in the nameof the present inventor are herein expressly incorporated by referencein their entirety.

The invention relates to the use of micro or nano technology in theproduction of renewable fuels and, in particular, of bio-diesel and allcorresponding by-products. In one embodiment of the invention, a streamof low cost, readily available, excess beef fat feedstock (a bio-dieselfeedstock) is transferred by any suitable pumping means under controlledpressure into manifolds (or ports), which feed micro-size conduits (orreaction tubes). This process reduces reaction time since the closeproximity of the reagents in the conduits enables reactions to occurmore rapidly and also produces controlled quantities of materials ofhigher value, such as bio-diesel, more rapidly than systems that use,for example, sodium hydroxide blended with triglycerides in a large tankor vat system. Furthermore solid catalysts such as silica can be fixedto the inner surface of the reaction conduits and vessels. Thisinvention includes preferred conditions to rapidly mix reagents by wayof static structures assembled from a series of plates (or discs)wherein each plate has depressions (or recesses) with profiles thatalign with depressions having corresponding mirrored profiles in eachadjacent plate. Typically, the plates are manufactured from, mostpreferably as a first instance, stainless steel and secondly, platesformed under high pressure such as by way of compression and/orinjection molding of suitable polymers. A series of conduits aremachined or molded such that when several plates are stacked together, aseries of uniform cross-section conduits traversing all plates, enablethe transfer of micro quantities of chemical feed stock through theenclosed spaces in which controlled reactions take place. After thereactions are complete, the newly formed materials are then transferredvia a series of conduits connected to manifolds that traverse thestacked plates in a similar fashion to those provided for the feed stockmaterials. A purpose of this equipment is to enable the manufacture ofsmall quantities of chemicals that may otherwise require very costlyapparatus and processes.

An additional benefit of the process disclosed herein includes thereduction in the quantity of water ordinarily required for preparingbio-diesel manufactured with sodium hydroxide or potassium hydroxide ascatalysts. Very large quantities of water are required to “wash”bio-diesel prior to consumption in, for example, an internal combustionengine. Sodium hydroxide and/or potassium hydroxide are potentiallydamaging to, for example, injection and all exposed metal surfaceswithin an internal combustion engine. Corrosion can occur and the lifeof the subject internal combustion engine will be reduced. Thedisclosure below provides details of a process incorporating sub and/orsuper-critical CO₂ as the catalyst. L-CO₂ blended with the othercomponents, which may include a quantity of water, required to producebio-diesel after the reaction has occurred, can provide a low pH valuesuch as 5, 4, 3 and even as low as about 2.9. Elevated pressure on theorder of 500 psi at about 34° F. to 36° F. may be required to create theconditions under which such low pH will occur; conversely, when pressureis released under controlled reduction to ambient pressure, any CO₂ thatremains with the bio-diesel will quickly boil off, leaving no more thanthe bio-diesel and glycerol present.

A second aspect of the invention is directed to an improved separationprocess that uses an apparatus that comprises a single or series ofinterconnected hydro-cyclones or more specifically, enclosed and sealedcyclones using liquid/fluid carbon dioxide instead of water, wherein thecyclones are suitably enclosed, sealed and pressurized, save the inputand output ports. The input and output ports are connected to conduitswhich are enclosed by suitable valves, to maintain the carbon dioxide ata selected pressure such that the specific gravity of the liquid carbondioxide is maintained at a selected level, such as 58 lbs. closed cubicfoot. The cyclones are connected to, most preferably, centrifugal pumps,wherein a single centrifugal pump is connected via a conduit to theupper inlet of a cyclone. The fluid carbon dioxide containingtrigyceride-containing solids, such as ground beef, in suspension istransferred via a pressurized conduit which is connected to the cyclone.The ratio of solids in suspension to the carbon dioxide fluid can be onthe order of one part liquid carbon dioxide to 4 or 5 parts solids insuspension. In the case of ground beef, the particles of ground fat canbe separated from the lean beef particles. The fat, or more specificallythe fatty adipose tissue including some inseparable lean beef (musclestriations), is then processed by applying heat, then centrifuging andseparating the beef oil from the other solids. The solids are thenchilled and blended with other lean food products and the beef oil isused in the production of bio-diesel as disclosed herein. The cyclonesincorporated in the process of beef oil extraction are described ingreater detail below.

The foregoing aspects and many of the attendant advantages of thisinvention will become more readily appreciated by reference to thefollowing detailed description when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a full set of laminae in an exploded view, according to thepresent invention;

FIG. 2 shows a three dimensional view of a collection of four platesarranged to provide a series of connected conduits within whichcontrolled chemical reaction can take place, according to the presentinvention;

FIG. 3 shows the outline of conduits created when the apparatus of FIG.2 is assembled. Inlet conduits connected via manifolds and enclosedspaces to outlet conduits arranged adjacent to one another, according tothe present invention;

FIG. 4 shows cross sectional illustrations of the conduits and spacesenclosed within four corresponding plates that are stacked and clampedtogether, according to the present invention;

FIG. 5 shows the behavior of three fluid streams combined into a singlestream shown immediately after combining and then after transfer intothe enclosed space of a reaction chamber, according to the presentinvention;

FIG. 6 shows a diagrammatic representation, generally in plan view, ofan application where the present invention is applied, according to thepresent invention;

FIG. 7 shows a preferred embodiment of an apparatus, wherein acentrifugal reaction process is illustrated, according to the presentinvention:

FIG. 8 shows the chemical reaction of triglycerides and methanol toproduce fatty esters and glycerol, according to the present invention;

FIG. 9 shows a 3D view of an apparatus designed for the production ofbio-diesel, according to the present invention;

FIG. 10 shows a preferred embodiment of an apparatus, wherein a rotatingreaction member provides mixing means according to the presentinvention.

FIG. 11 is diagram showing steps in a production configuration that canbe arranged to produce bio-diesel and other components of a chemicalreaction plant matter.

FIG. 12 a plan view of a diagram showing a preferred method ofbio-diesel and glycerol production.

FIG. 13 is a table showing a range of temperatures and pressures thatcan be maintained to achieve maximum efficiency of a particularreaction.

FIG. 14 shows a hydrocyclone that may be used to separate lean beef frombeef fat in accordance with the present invention.

FIG. 15 shows a cross-sectional view of the hydrocyclone of FIG. 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The apparatus and processes described herein are most preferably usedfor the production of bio-diesel. The apparatus shown herein comprises aseries of three dimensional views of a micro reactor with detailsshowing the manifolds and conduits providing a general understanding ofthe operation and approximate size of the apparatus. 4000 and 4008 inFIG. 1 represent length by width, respectively, of the plan view of astacked and assembled grouping of laminae wherein the diameter of 4000equals approximately one inch and the diameter of 4008 is ¾ of an inch.The thickness of a typical laminae is represented by 5042 and is on theorder of 1/16 of an inch. The diameter of manifold 4020 is approximately⅛ of an inch. Hence, the equipment described herein is generallyreferred to as “micro technology”.

The reaction residence time during which the blended materials requiredfor the reaction are retained in the reactor (vessel) of a typical macrobio-diesel production system is on the order of 7 hours, whereas thereaction time for the micro-technology described herein can be on theorder of 20 seconds. It can therefore be seen that relativelysubstantial quantities of bio-diesel can be produced by the microequipment when compared with macro equipment production rates. Anintegrated micro structure is provided by stacking several flat sections(or plates) of selected material, wherein each flat section is machinedor molded to provide channels, vessels, ports and conduits that maycommunicate directly with adjacent flat sections. The inlet and outletports of each flat section are located in common positions such thatwhen stacked together the outlet port of a first flat section cancommunicate directly with the inlet port of a second adjacent flatsection, which are connected together such that their inlet and outletports are connected by a series of channels and enclosed chambers inwhich the chemical reaction required to produce renewable fuels can takeplace. In this way, flat sections are connected together via outlet andinlet ports and the inlet and outlet ports of each flat section areconnected by a series of channels and enclosed chambers specificallydesigned to facilitate the chemical reaction required to producerenewable fuels or bio-diesel. The stacked laminae formed from the flatsection (with slots, perforations, grooves, recesses, channels andvessels), are carefully arranged to provide a series of reticulatingconduits within which, when stacked and held firmly together, immiscibleand/or miscible fluids alike, can be blended together thoroughly in themicro channels, vessels and miniature reactors to ensure contactbetween, in particular, immiscible fluids such as fluid beef tallow andmethanol or ethanol. Such thorough mixing can occur with dissimilarmaterials that ordinarily may repel each other. The reaction to producebio-diesel and glycerol is shown in FIG. 8.

Additionally, it is a purpose of the new technology disclosed herein tofacilitate enhanced quality of food and, in particular, the quality ofbeef harvested, typically, from either steer or heifer sources whereinthese animals are slaughtered at the age of about 30 months or less ormore, enhancing beef flavor, tenderness, mouth-feel and aroma whilefacilitating the low cost production of low cost bio-diesel from animalfat harvested from the slaughtered animals. Animal fat sources mostpreferably from cattle and having been lot fed to attain a body weightgreater than 1,200 lbs will be more abundant than if the animals aresmaller. Typically, steer and heifers can be transferred to lot feedingfacilities at the age of, for example, 1 year to 2 years and then theanimals may be retained in the lot feeding facility for a period ofseveral months, but generally, significantly less than 12 months. Theperiod of time that the cattle are held is determined by the weight gainof individual animals. The animals will generally be released forslaughter when they reach an approximate weight of 1,200 lbs. Somecattle attain this weight by or before the age of 15 months, whereasothers may take significantly longer and in some cases never reach thistarget weight. So, it is a purpose of this invention to provide anincentive to cattle “feeders” to retain cattle at the lot feedingfacility for a period of time determined by the attained body weight ofeach animal. Furthermore, it is intended to encourage feed lot operatorsto allow cattle to be finished and released for slaughter only when asignificant quantity of beef fat has become available for harvestingfrom the carcasses after slaughter. More particularly, it should benoted that cattle around the age of 15 to 24 months have a capacity toconsume vast quantities of feed. Little exercise is required for theanimal located in a feed lot since feed is available within a shortdistance, even from the furthermost point in each pen of the feedinglot. Therefore, little exercise is possible, although sufficient tosatisfy the natural requirements of cattle, which are quite differentfrom other animals housed in intensive breeding and rearing facilities.Briefly, intensive breeding and animal rearing procedures compriseenclosure of, for example, sows in breeding pens that restrict them fromeven turning around. Such an example is typical and the pigs have beenbred by selecting those animals with the most suitable characteristicsfor enclosing within the intensive rearing facility. Conversely, cattlecannot be intensively farmed, particularly during the first few monthsof the animal's life, at least not with the currently predominant cattlebreeds and they must be enclosed within pens having at least one hillthat they can climb and also the provision of feed and water close by.The typical heifer and steer body weight of 1,200 lbs enables harvestingof more than 200 lbs of fat (white adipose fatty tissue) from whichproteins, collagen and connective tissue must be separated from thefatty tissue prior to the production of bio-diesel from said fat.Approximately 8 lbs of oil (tallow; in particular, beef tallow having nosolids or other contaminants) with a proportioned quantity of methanol(see below for specific quantities) can produce about one gallon ofbio-diesel.

It is a purpose of this present invention to provide encouragement tocattle feed lot operators to retain animals for a longer period and inthe feed lot facilities so that the quantity of fat yielded from eachanimal is increased. It is anticipated that such increase would be equalto at least a 50% more than is currently available. The benefit of thisprospect far exceeds the associated costs. A 1,200 lb steer or heiferconsumes vast quantities of feed; however, the conversion rate canexceed 25% at this stage of their life cycle. Therefore, adopting thismethod of producing fat for production of bio-diesel is substantiallyless costly than, for example, sourcing similar fat from plant mattersuch as seeds or beans (such as soy beans). Costs inevitably incurred inthe production of oil derived from plant matter include the crushingplant costs, which is on the order of $60 million. Therefore, to extracta quantity of oil from virtually any plant source requires thecultivating of the appropriate plant (e.g., soy beans) to be harvested.The separation of seeds or beans from the supporting plants thencrushing the beans or seeds, results in a relatively small quantity ofextracted oil when compared with the value or cost of entire livingplant, most of which is lost. In fact, greater than 75% of the energystored in a plant having been derived via photosynthesis from the solarsource, is lost. When compared with fat derived from an animal source,it can be seen the plant matter wasted in producing oil by way of plantcultivation is 75% which is comparable to the feed loss with a 25%conversion rate. However, the conversion rate of feed in cattle of 20months old is greater than 25% and the animal fat source does notrequire new fat extraction crushing plant and equipment.

Desirably, bio-diesel shall be produced according to the processesdisclosed herein by the trans-esterification of triglycerides harvestedfrom cattle (or plant matter of suitable type or genus). In oneembodiment, CO₂ is used as a catalyst in suitable proportion to the beeffat or oil at appropriate temperature and pressure as required tomaintain the CO₂ phase most suitable for the maximized bio-dieselproduction. These processes may use micro and/or nano technologies suchas those recently developed at ONAMI Pacific North West Laboratories orOregon Nano Science and Micro Technology Institute. ONAMI have developeda micro scale production plant for the manufacture of bio-diesel fromplant materials. In addition, SafeFresh Technologies, LLC have developedprocesses incorporating CO₂ as the catalyst, medium, refrigerant,antimicrobial and propellant, all employed in a process that has nowreached commercial operation. By combining these two separatetechnologies, the investor has developed an efficient process forbio-diesel production. The processes may utilize micro technology suchas the ONAMI bio-diesel micro technology, as disclosed in associationwith FIGS. 1-5. Notably, unlike the technologies developed by ONAMIwherein catalysts such as silicon, sodium hydroxide, potassium hydroxideand other solid structures form a component of the micro equipmentdeveloped by ONAMI, the present methods may displace other moreconventional catalysts with L-CO₂. The reactions (between thetriglyceride fat molecules and methanol and/or ethanol) can be enabledwhen liquid CO₂ or, alternatively, dense phase critical CO₂ which isthoroughly miscible with said triglyceride animal fats is combined witha proportionate quantity of methanol and/or ethanol.

In some embodiments, the reaction between methanol and/or ethanol andtriglycerides with a suitable catalyst yields approximately 20 grams ofglycerol with every 100 grams of bio-diesel. Furthermore, it ispreferable that excessive methanol and/or ethanol be provided andtherefore, the residual methanol and/or ethanol will comprise acomponent of the resultant mixture. Said mixture contains bio-diesel,glycerol, methanol and/or ethanol and CO₂. In any event, the resultantmixture of liquids is desirably separated prior to using the bio-dieselas a liquid fuel.

In particular, the apparatus disclosed in association with a series offigures describing an enclosed pressurized vertically disposed (orhorizontally disposed) decanter-style centrifuge arranged to separateliquids and solids from liquids and solids into separated, isolatedstreams. In one preferred embodiment, the separation of glycerol andbio-diesel can be achieved by “spray-freezing” the resultant fluid asdisclosed herein. The separated streams of methanol, ethanol, water andCO₂ can then be recycled with bio-diesel transferred into suitablestorage vessels. A hydrocyclone separation apparatus is shown in FIGS.14 and 15.

Referring now to FIG. 1, a three dimensional view of an apparatuscomprising a series of plates or lamina such as 4040 and 4044 arearranged in symmetrical groups of 4× lamina each, between an upper endplate 4014 and a lower end plate 4092. The view in FIG. 1 is “exploded”and 5 groups of 4× lamina, or flat sections, are shown in an expandedview and spread apart. The apparatus when in closed position, such thatall laminae are held in tight contact with adjacent lamina, heldtogether by said end lamina 4014 and 4092 in such a manner that suitableclamps exert such pressure so as to close end plate 4014 toward opposingend plate 4092 with a closing pressure sufficient to inhibit leaking ofany pressurized fluids that may be transferred through ports, conduitsand vessels provided within the assembled flat sections, generallyprovides a fully enclosed system, other than inlet and outlet portswhich are also sealed tight in connections to corresponding supply andremoval conduits, preventing escape of any fluid to atmosphere, havingconduits communicating and connected in a manner that is described asfollows:

Port 4002 connects directly with a series of ports having a center lineparallel with arrow 5046 and extending through all flat sections, platesor lamina with an end plate 4014 through plate 4080 and enclosed at alower end by plate 4092, thereby creating a conduit into which fluid canbe transferred, wherein said fluid can transfer via conduits parallelwith manifolds 5044 and 5045, and all manifolds of similar length to5044 and 5045, wherein said manifolds connect each group of conduitstogether such that the fluids transferred therein can be extracted byconnecting to extraction conduits (such conduits not shown). Ports 4020and 4022 connect directly with ports 4038 and 5016 respectively, thenplates 4082 and 4084 respectively and so on to provide two parallelconduits in direct communication with a series of perpendicular conduitssuch as those defined by recesses 5031 and 5039. Recess 5031communicates with a series of connection tubes 5026, 5038, 5036, 5034and 5032 with similar and corresponding connection tubes communicatingwith recess 5039. It can therefore be understood that fluid transferredinto port 4022 in the direction shown by arrow 5048 can enter recess5031 and from recess 5031 into connection port 5026, etc. Similarly,fluid transferred in the direction shown by arrow 4010 into port 4020can flow into conduit segment 4038 and then into recess 5039 and so on.The conduits or recesses arranged between laminae such as 4014 and 4040are arranged to communicate in such a manner that bio-diesel and aproportionate quantity of glycerol can be manufactured in the apparatus.When fluids comprising beef fat are blended with a proportionatequantity of liquid CO₂ then transferred into port 4002, a quantity equalto about 20% by volume, for example, of fluid transferred into port 4002is transferred via ports 4020 and 4022. The conduits provided arearranged to combine a suitable quantity of methanol and/or ethanol witha corresponding quantity of blended liquid CO₂ and beef tallow such thatcontact between molecules of beef fat and molecules of methanol and/orethanol occurs, resulting in a reaction between the methanol and/orethanol and the triglyceride molecules of the beef tallow, resulting inproduction of bio-diesel which then transfers into reaction chambers,the detail of which shall be provided below.

Five assembly groups of lamina are shown in FIG. 1 in exploded viewbetween end plates 4014 and 4092 including a first assembled group ofplates 4040, 4044 and 4046. Each group of lamina are similar and areprofiled with slots, recesses and ports that correspond with theprofiles of adjacent lamina to provide a series of conduits and reactiontubes connected directly with input ports 4002, 4004 and 4020 which cancommunicate there through with extraction ports such as 4026, 4028through 4036 and also a corresponding series of ports including port5022. FIG. 2 shows the outline of a similar grouping of laminae such as4040, 4044, 4046 and 4047 (of FIG. 1) with the outline of extractionports 4026, 4028, 4030, 4032, 4034 and 4036 (of FIG. 1) and inputconnection ports 4038, 5016 and 5017 which together correspond withports 28, 32 and 30 (of FIG. 2), which connect to distribution conduits(or manifolds) such as 5031 and 5039 (FIG. 1), transfer tubes such as5034, 5036 and 5026, which connect with reaction tubes such as 245 or288 in FIG. 3 which in turn connect with reactor vessels or reactionchambers such as 274 or 254 in FIG. 3 which collectively communicatedirectly between said input ports and output ports of an outputmanifolds of FIG. 1. Said series of 5 laminate groupings shown inexploded view and spaced apart in-line between end plates 4014 and 4092(of FIG. 1) are each constructed and arranged in like fashion as theoutline of members 40, 44, 76 and 46 as shown in FIG. 2, all generallyarranged such that when assembled and held compressed, by any suitableset of tie-rods (not shown) for example, between said end plates 4014and 4092, bio-diesel can be manufactured within such an enclosed seriesof micro channels and conduits with an input stream provided via feedingtubes connected directly to manifolds such as 4012 and 5040 of FIG. 1.

Referring again to FIG. 1 and, in particular, inlet ports 4002, 4020 and4022, it should be noted that fluids transferred therein will follow themicro conduits such as 5031 and 5039 and then through ports such as 5036and 5034 and after reticulating through the micro channels and reactionchambers, bio-diesel and glycerol will transfer through extraction portssuch as 5008 in the direction shown by arrows 5006 and 5010 to connectwith manifold 5000 or manifold 4088 and then through outlet ports suchas 4087 in the direction shown by arrow 4093 provided in manifold 4088or, alternatively, through outlet port 5001 of manifold 5000 in thedirection shown by arrow 5003.

Referring now to FIG. 2, ports 28 and 32 are arranged to providecommunication with reactor vessels such as 22 and 38. First, fluidcomprising a blend of refined beef tallow and any suitable fluidcatalysts such as L-CO₂, sodium hydroxide or potassium hydroxide blendedtogether can be transferred through port 30. Port 30 communicates withconduit 35, enabling transfer of said first fluid to be transferred viaconduit 35 and then into connection tube 23 and into reaction conduit24, followed by reaction vessel 22. The reaction vessels 22, 38 and 50,for example, which are connected to reaction conduits 24 and 36, aretypical examples of preferred profiles for most efficiently producingbio-diesel from the fluids provided therein. Conduits 35, 26 and 66 areexamples of conduits provided to transfer fluid prior to reactiontogether. In particular, fluids transferred via port 30 combine withfluids transferred via ports 28 and 32 within reactor conduits such as24 and 36 which, in turn, communicate with reaction vessels 22 and 38respectively and similar to, for example, reactor conduit 74 or reactorvessel 64. Fluids transferred via port 30 are ultimately sandwichedabove and below, in intimate contact with fluid transferred via ports 28and 32 as described below in association with FIGS. 3, 4 and 5, and inparticular, as shown in FIG. 5, section “B-B”.

Referring now to FIG. 3, the outer profile of a complex manifold-likeimage is shown with solid lines, projected in a three dimensional view.Again, the outline shown in FIG. 3 corresponds to the groupings ofplates shown in three dimensional view in FIG. 2 which also correspondswith the assembly of 5 groupings of 4 laminae each (such as 4040, 4044,4046 and 4047) shown in FIG. 1.

The three dimensional image shown in FIG. 3 comprises a series of inputports 228, 234 and 240 (also referred to as manifolds) which correspondwith inlet ports 30, 28 and 32 as shown in FIG. 2. Fluid transferredinto port 234 in the direction shown by arrow 232 ultimately becomessandwiched between fluid transferred via port 228 in the direction shownby arrow 230 and port 240 in the direction shown by arrow 236. Fluidtransferred via port 234 is ultimately sandwiched between fluidtransferred via port 228 and fluid transferred via port 240 in such away that contact between molecules of the fluids enables the rapidproduction of bio-diesel according to the reaction shown in FIG. 8.

In one preferred embodiment, a blended fluid comprising a catalyst suchas L-CO₂ combined with ethanol and/or methanol collectively maintainedat a suitable pressure such as 1,100 PSIG or greater and temperaturesuch as 90° F. or greater (to ensure fluid L-CO₂ is maintained in asuitable, super critical phase) is transferred at a controlled andadjustable rate into ports 28 and 32 of FIG. 2 which connect withlateral conduits 34 and 66 and also 26 and 69. Corresponding lateralconduits are arranged in pairs with, for example, lateral conduit 26located above reaction conduits 24 and 74 with vertically disposedconnection tubes such as 70. A supply of fluid comprising beef fathaving been separated from substantially all other source materialsolids (e.g. proteins and connective tissue) is transferred undercontrolled pressure (e.g., about 500 psi) through port 30 which, inturn, connects with a lateral conduit such as 68 and then withconnection tubes such as 23 and 65 before direct transfer at aperpendicular disposition to a reaction conduit such as 24. The reactionconduit 24 connects directly to reactor vessel 22 which has a profileflattened to ensure a broad exposure between fluids transferred therethrough.

Referring to FIG. 2, it can be seen that a controlled supply of liquidbeef fat transferred via port 30 and into lateral conduit 68 can bepumped under selected pressure into reaction conduits such as 74, 24 and36. Said reaction conduits connect directly to enclosed flattenedreaction vessels such as 38, 50, 64 and 22. In this instance, theenclosed reaction vessels are arranged to ensure the contact between thecatalyst super-critical CO₂ with methanol and/or ethanol and beef fattransferred into said reaction vessels. The lateral connection tubessuch as 26 and 69 are arranged to transfer L-CO₂ and methanol and/orethanol simultaneously into the upper zone of reaction conduits vialateral conduit 26 and into lower zone of reaction conduits by lateralconduit 69. In this way, beef fat is transferred at a suitabletemperature via distribution port 30, lateral conduit 68 and verticaltransfer connection such as 23, directly into an end of conduit such as24 such that the single stream of beef fat is transferred along areaction conduit such as 24 which is then sandwiched between upper andlower streams of fluid transferred via lateral conduits 26 and 69, forexample. A fundamental purpose of the arrangement of conduits andreaction cavities shown in FIG. 2 is to ensure that contact is madebetween beef fat and said CO₂ catalyst with methanol (or ethanol). Theapparatus shown in FIG. 2 comprises a series of flat parallel sided,adjacent lamina or plate assemblies arranged together (as shown in FIG.1 in exploded view between conduit terminating end plates 4008 and4092). Extraction tubes can be directly connected to each manifold 4088and 5000 to extract the resultant fluid after the reaction is complete;the resultant fluid comprising bio-diesel, glycerol, methanol and/orethanol and any other catalysts that may have been used, may then beseparated into the components of bio-diesel, glycerol, methanol andother matter such as impurities.

Referring again to FIG. 2, a three dimensional view outlines theconduits formed into 4× plates or laminae when they are stacked togetheras shown in FIG. 1. The rectangular plates or flat sections are arrangedwherein an upper plate 40 and a lower plate 46 sandwiches plates 44 and76 there between. An outline of cavities such as conduit 36 and enclosedvessels such as 38 and 64 which connect a series of conduits toextraction ports 10, 12, 14, 16, 18, and 20 and also 62, 60, 58, 56, 54and 52 respectively, created by assembly of the four plates, can also beseen.

Referring now to FIG. 3, the outline of all inner conduits and transfertubes in a section comprising 3× plates with feeding ports, lateralmicro conduits with perpendicular reaction tubes and enclosed reactionvessels connected to extraction manifolds is shown with arrows such as278, 302, 316, 224, 327, 221, 212, 270, 266, 218 and 253 showing theflow and direction of each stream of fluid through each conduit segment.It should be noted that a series of solid lines shown in FIG. 3correspond with broken lines shown in FIG. 2 wherein inlet ports 28 and32 correspond with 228 and 240 of FIG. 3. Fat distribution manifold 234corresponds with conduit 30 of FIG. 2; lateral conduit 26 correspondswith 226 of FIG. 3 and so on, with reaction conduit 222, for example,corresponding with reaction conduit 24 which is shown in FIG. 2.

Referring again to FIG. 3, lateral conduits 226 and 292 connect withfluid supply port 228 such that said fluid transferred under controlledpressure and temperature in the direction shown by arrow 230 throughsaid port 228 is pressurized such that quantities substantiallycontrolled by the cross sectional diameter of lateral conduits 226 and292 provide an enclosed pathway for the material supplied in thedirection shown by arrow 230 to flow in the direction shown by arrowssuch as 224 and 320 and then in the direction shown by arrows such as293 and 317. Fluid transferred via conduit 226 in the direction shown byarrow 224 is subsequently divided equally so as to flow viaperpendicular conduits such as 294 in direction shown by arrow 317. Inlike fashion, fluid transferred in the direction shown by arrow 236through port 240 is divided proportionately by transfer through lateralconduits such as 238 and 244 flowing in the direction shown by arrows235 and 242 respectively. Perpendicular transfer tubes such as 286 and246 provide sealed pathways for fluid transfer in the direction shown byarrows 283 and 325, respectively. Blended fluid streams transferred viaconnection conduits such as said 286 and 289 is transferred into anupper region of reaction conduit 288 volumetrically and substantiallyequally. The combined mass flow of the streams transferred throughperpendicular connection tubes such as 286 in the direction shown byarrow 283 is equal to the mass flow of fluid transferred via port 234(FIG. 3).

It can therefore be readily understood that in this way, fluids and/orsuspensions transferred via ports 228 and 240 in the direction shown byarrows 230 and 236 respectively, can be distributed into reactionconduits such as 245, 323, 338, 300, 314 and 322. A stream of fluidrepresented by arrow 232 is pumped under pressure (480 psi to about 600psi) along port 234 and is subsequently divided into equal but separatestreams of fluid traveling in the direction shown by arrow 297 which isthen divided into 12 streams comprising six (6×) pairs of streamsincluding the stream represented by arrow 298 in conduit (or reactiontube) 300 above and the stream shown by arrow 287 in conduit (orreaction tube) 288. The fluid beef fat is therefore sandwiched between apair of layers transferred into said reaction tube such as 300 viaperpendicular conduit 294 on a first side and via conduit 296 on theupper or opposite side.

The mass flow of combined fluid transferred into ports 228 and 240 maybe arranged such that it corresponds to the mass flow of fluidtransferred via port 234 in the direction shown by arrow 232 such thatthe mass flow of the upper and lower streams, for example, transferredinto conduit 338 via conduit 286 in the direction shown by arrow 283when combined with a stream transferred into the lower zone of conduit288 via conduit 289 will flow in the direction shown by arrow 287 at arate substantially equal to the velocity of the fat stream transferredinto reaction port 338. Most preferably the velocity of upper and lowerstreams transferred into reaction conduits such as 245 is substantiallythe same as the velocity of fluid fat material transferred from port 234and lateral tube 297. It can be seen in FIG. 3 that the profile of eachreaction conduit such as 245 changes as it approaches the extractionmanifold such as 258. In fact, the width at region 254 of conduit 245 issubstantially increased while the depth is substantially reduced. Thiscauses the three streams transferred into reaction conduit 245 to becomeflat, parallel sheet-like streams moving in direction shown by arrowssuch as 251, 253 and 257. In this way, the stream of beef fat materialis exposed to relatively large upper and lower surface areas, therebyencouraging rapid reactions.

Referring now to FIG. 4, a series of cross sections through a selectedsection of 4× laminae or plates 3004, 3008, 3012 and 3014 are assembledtogether to provide an exemplary side view of the multiple laminae ofthe apparatus shown in FIG. 1. Ridges (e.g., 3002) in plate 3008 arelocated around the perimeter of both the upper and lower sides and withsimilar plate 3014 also having ridges, thereby providing a registrationfor the alternately stacked plates of 3004 and 3012 to accurately locaterelative to adjacent plates 3008 and 3014. In this way, recesses such as3070 and 3068 in adjacent plates 3054 and 3058 (which correspond toplates 3012 and 3014, respectively), provided in the surface of eachplate and which are intended to be aligned correspondingly, can bealigned by locating plate 3054 against the ridges of plate 3058 andplate 3096 (which corresponds to plate 3008), respectively. In this waythe conduits passing through the entire stack of plates such as 3050 and3020 are easily aligned and lateral conduits such as 3082 and 3070formed from depressions provided in adjacent plates are readily alignedwhen the plates are assembled together. Cross section “A-A” passesthrough lateral and vertical conduits as shown in section “A-A”.

The purpose of the arrangement shown in connection with FIGS. 1 through5 is to enable the exposure of triglyceride molecules to methanol orethanol with the appropriate catalyst such as L-CO₂ in the most rapidway possible. It is a purpose of this arrangement to sandwich a layer oftriglycerides blended with L-CO₂ between two layers on opposite sidescomprising methanol and/or ethanol and any other suitable catalyst suchas sodium hydroxide if necessary. A blend of L-CO₂ and triglycerides istransferred from conduit 3034 to conduit 3082 and 3073 via verticallydisposed connection tube 3032. The blend enters conduit 3082 at 3077 andsimilarly fluid enters conduit 3068 at 3073. Arrows show the directionof flow and the sandwiching fluid comprising a blend of methanol and/orethanol can be transferred into conduit 3068 via vertical conduit 3042from one side and via conduit 3071 on the alternate side. The combinedthree layers then transfer through a blended section at 3048 and 3066 atwhich point the profile of the circular cross section of a fluid inconduit 3068 changes as it travels through the areas shown as 3048 and3066 where the fluid is fanned out as it conforms to the change inconduit profile at 3064 and 3062. The reactive fluid is then transferredinto conduit 3050. In a similar fashion, fluids are transferred intoconduit 3026 in the direction shown by arrows 3028 and 3024 and fromthere through profile changing segment 3023 and into the widened andflattened segment 3022. Referring now to sections “B-B” and “C-C” asshown in FIG. 5 firstly, it can be seen in section “C-C” that thetriglyceride fluid 3202 is penetrated by oval beads 3214 and 3204.Referring now to section “B-B” the profile of the triglycerides 3102 andethanol and/or methanol materials has been divided to provide maximumexposure such that layer 3102 is sandwiched and in close proximity tothe fluids shown as 3100 and 3104. Section “B-B” of FIG. 5 shows anenlarged view of the reaction enclosure as described in connection withthe earlier figures. In this way, maximum exposure between thetriglycerides and ethanol and/or methanol is provided thereby rapidlyproducing bio-diesel and glycerol by ensuring a more complete reaction.

With appropriate quality control measures in place, the assuredconsistency of materials produced via the micro equipment and methodsherein described provide tightened and more accurate tolerances to therespective reactions and subsequently more consistent production rateswhere reaction time is measured in seconds as opposed to hours for thecurrent macro bio-diesel production technology commonly used.

Referring again to FIG. 3, in a preferred embodiment, warmed, liquid,filtered beef fat, can also be blended directly with methanol and/orethanol and then transferred via conduit 234 in the direction shown byarrow 232 and into the ends of reaction transfer conduit such as 288.Therefore, controlled quantities of feed stock materials useful forproduction of bio-diesel by way of chemical reaction enhanced bysuitable catalysts are directed by transfer through micro conduitsdirectly into reaction tubes, within which solid catalysts can be fixedto the walls, designed to create close and thorough contact of thematerials and the alteration of reaction tubes profiled wherein thediameter is reduced in the vertical plane and increased in thehorizontal plane in blended gradual profile change wherein at the entryend of reaction conduit such as 3047 in section “A-A” is a circularprofile (FIG. 4), as can be seen in section “C-C” (FIG. 5).

Referring again to FIG. 4, a fluid transferred through conduit 3032 isdivided between two opposing connection tubes 3075 and 3077. Opposingrecesses 3034 and 3036 in plates 3096 and 3094 create an enclosedconduit when the adjacent plates are in contact. Alternate plates arearranged to mate with each adjacent plate. Ridges such as 3052, 3002 and3056 follow a path around the perimeter of the female plates. As can beseen, male plates such as 3051 (which corresponds to plate 3004) and3094 penetrate the female plates when in contact such that conduits suchas 3050 and 3020 are created. Male plate 3054 with adjacent femaleplates 3096 and 3092 provide a reaction tube 3047 connected at a firstend to connection tube 3075 and at a second end to vessel sections 3062and 3064. The circular cross sectioned reaction tube 3047 connects via atapered region 3048 and 3066 to low profile vessel sections 3064 and3062 in such a way that fluid transferred in the direction shown byarrow 3042 through conduit 3044 contacts fluid transferred throughconnection tube 3075 intimately. Correspondingly, fluid transferredthrough conduit 3071 into reaction tube 3047 also contacts fluidtransferred via connection tube 3075 on the alternate side of fluidflowing in direction shown by arrow 3074 and collectively three separatestreams of fluid combine within reaction tube 3047 and are transferredin the direction shown by arrows 3038 and 3074 through upper and lowertube segments 3070 and 3068 comprising reaction tube 3047 throughtapering zones 3048 and 3066 and into low profile vessels 3064 and 3062.

Section “A-A” shows a lateral cross section of four assembled andengaging plates 3018, 3096, 3094 and 3092 and the pathway created by theassembly of said plates. In this assembly, a first fluid is transferredvia tube 3032 into reaction tubes 3026 and 3047, where a second streamof fluid transferred via conduit 3030 and a third fluid transferred viaconduit 3076 in the direction shown by arrow 3078 sandwiches said firstfluid stream transferred via conduit 3030. Said first, second and thirdfluids subsequently combine in a single stream which is transferredcollectively in the direction shown by arrows 3028 and 3024 via taperingsection 3023 and into low profile sections 3022 and 3086. Section “A-A”also shows a second reaction tube 3047 wherein a first fluid transferredvia conduit 3032 in the direction shown by arrow 3073 is subsequentlysandwiched between a fourth fluid stream transferred via conduit 3044 inthe direction shown by arrow 3042 and a fifth fluid stream transferredvia connection conduit 3071. The combined stream of first, fourth andfifth fluids is transferred in the direction shown by arrows 3038 and3074 through tapering sections 3048 and 3066 and into low profilesections 3064 and 3062.

Section “C-C” in FIG. 5 shows a cross section of reaction tube 3206containing a combined stream of said first fluid 3202 sandwiched betweensaid second fluid 3204 and said third fluid 3214. Section “C-C” has beenillustrated for the purpose of showing the intimate contact of maleplate 3208 and female plate 3212 in direct compressed and close contactalong interface 3200 wherein reaction tube 3206 is thereby facilitatedwhich enables said first fluid 3202 to be in close and intimate contactwith said second fluid 3204 and said third fluid 3214. The ellipticalprofile of said second fluid 3204 and said third fluid 3214 are bothtransformed, after transfer via tapering section 3023 as shown insection “A-A” in FIG. 4, into sheet profiled layers 3114 and 3110 shownin section “B-B” in FIG. 5 sandwiching said first stream 3112.

Referring again to section “B-B” in FIG. 5, a pair of plates 3098 and3108 are shown in intimate contact along interface 3102. This figureshows the profile of vessel 3022 in section “A-A” in FIG. 4 with saidfirst stream 3112 sandwiched between said second stream 3114 and saidthird stream 3110. Section “B-B” indicates how said first, second andthird fluid streams 3112, 3114 and 3110, respectively, are in closecontact such that the reaction time between said first, second and thirdstreams can be reduced.

It can be seen, therefore, that first, second and third fluid streamstransferred via conduits 3036, 3030 and 3076 in section “A-A” arecombined in such a way to enable reduced reaction time by altering thecombined stream profile of said first, second and third fluids as shownin section “B-B” as layers 3112, 3114 and 3110, respectively. The closeproximity of said three streams is facilitated by combining said first,second and third streams into a circular section conduit 3206, as shownin section “C-C”, which is then transformed into a low profile sectionas shown in section “B-B”, facilitating the combining of fluids whichmay repel each other due to a physical property, but which nevertheless,can be encouraged to react by altering the combined stream profile 3104as shown in section “B-B”.

Referring now to FIG. 6, a view of the entire process is shown by way ofdiagrammatic representation line drawings. Cattle at 6000 enter theslaughterhouse 6004 along path 6002 and data downloaded from RFID tagswhich have previously been either embedded in the animals' neck musclesor any other method known in the art. Immediately following slaughterand evisceration, the carcasses are graded in factory represented bysquare line drawing 6004. After removal or harvesting from animalcarcasses low value fat is transferred via 6008 to processing plant 6010where either electric power or liquid fuels can be efficiently convertedfrom this by-product. After slaughtering and chilling the animalcarcasses, they are transferred via 6006 to processing plant 6012 wherethe animals are graded and stored. After quartering the animal anddownloading information about the animal to RFID tags, special apparatussuch as transponders can be arranged to check outgoing beef quarterswhich are transferred to the adjacent building 6034 where animals arede-boned and sliced to produce retail package cuts of beef and theremaining trim or boneless beef for ground beef production. Somepackages are shipped out of 6034 in the opposite direction of arrow6018, but the majority of packages are transferred in the direction ofarrow 6032. Approximately 40% of the weight of boneless beef received in6012 is transferred into an adjacent room 6036 for the purpose ofgrinding boneless beef. Liquid and gaseous CO₂ is transferred via 6028from pressure vessel and storage tank 6026. The boneless beef is treatedwith a CO₂ snow and can be packaged in barrier chubs and stored in area6038 after transfer from the factory area 6036 along 6030. While groundbeef can be packaged in chubs, at this point most likely the bonelessbeef transferred into area 6036 will be graded and grouped intoapproximately one ton palletized quantities which are typically treatedwith CO₂ snow. Any chub production would be from the high lean gradessuch as 85% lean through 94% lean. Boneless beef streams comprisetypically grade groupings of 75% VL (75% lean beef) or 65% VL and 50%VL. Lower grade described as 30's, comprise the remaining fat streamwith any quantities up to 30% lean and perhaps 40%. These remainingpalletized streams are transferred into separation enclosures via 6042.In this area, all boneless beef is ground and automatically separatedinto streams of any quantity ordered by customers such as 85% leanground beef, all of which may be packaged in barrier chubs or,alternatively, case ready retail packages. The process of separationemploys quantities of CO₂ which can be sourced from tank 6026 viaconduit 6023 and returned after use for recycling via conduits 6044 and6024. Packages shown as 6058 have been packaged in regions 6050 and6054. The fat stream removed in area 6040 is then transferred to area6066. The stream of white fatty adipose tissue is centrifuged and allproteins removed are returned to area 6040 in the direction shown byarrow 6045 and is then included in ground beef production, all of whichis transferred in the direction shown by arrow 6048. After removal ofsolids from the fat stream at 6066, the beef fat which is now in a warmfluid condition is filtered prior to transfer in the direction shown byarrow 6068 to 6070, where it is combined with a suitable mixture andcontrolled quantity of liquid CO₂ under appropriate pressure which isthen transferred in the direction shown by arrow 6074 to 6086. 6086 isrepresentative of apparatus shown in FIGS. 1 through 5, 7 and 9 through10. Bio-diesel and glycerol are produced in this way and glycerol istransferred in the direction shown by arrow 6076 to storage area 6080where the viscous liquid glycerol is refined and transferred tocustomers at 6084 in the direction shown by arrow 6082. Bio-dieseltransferred in the direction shown by arrow 6088 and stored at 6092 canbe filtered and further refined using the method described below.Refined bio-diesel is transferred via 6094 to processing area 6096 wherefossil fuel diesel transferred from 6100 in the direction shown by arrow6098 is blended with said bio-diesel to produce a range of bio-dieseland fossil fuel diesel blends such as B2 and B20. B2 represents a blendof diesel wherein 2% bio-diesel has been added. B20 represents dieselfuel containing 20% bio-diesel and 80% fossil fuel diesel. Thesefinished fuels are transferred in the direction shown by arrow 6102 foruse as fuel in automobiles, or any engine such as trains, electricgenerators, and the like.

Referring now to FIG. 7, yet another preferred embodiment is shown byway of a diagrammatic representation of a pair of spinning discstraveling in opposite directions. Housing 7010 encloses a pair ofmachined matched discs 7030 and 7028. The purpose of this apparatus isfor production of bio-diesel and glycerol from, most preferably, animalfats derived from unwanted beef fat. In order to produce bio-diesel andglycerol, the reactive ingredients are desirably blended together at asuitable temperature such as 70° F. or between about 65° F. and about130° F.

A disc 7030 manufactured from a suitable material such as 316 stainlesssteel which has been machined and surface treated, is shown. Disc 7030is fixed rigidly to centrally located perpendicular first drive shaft7004 via boss and bearing housing 7006. A second disc 7028 is shownadjacent to and parallel with disc 7030. Disc 7028 is mounted to a boss7020 with suitable bearing means and to a second drive shaft 7022. Driveshaft 7004 desirably comprises a heavy wall tube manufactured from asuitable material such as stainless steel and is provided with conduit7002 thereby allowing fluid to be transferred there through, forexample, in the direction shown by arrow 7000. Conduit 7002 can beprovided with drive means such as a variable speed electric drive thatcan rotate shaft 7004 in the direction shown by arrow 7001. A series ofapertures such as 7034 extending along a path parallel with machineddisc 7030 and around the circumference of boss 7006 communicate directlywith conduit 7002. Shaft 7022 can be provided with a driving motorcapable of driving in either direction and at any selected speed.Conduit 7024 communicates with a series of apertures such as 7029wherein said apertures follow a path parallel and adjacent to said firstseries of apertures 7034. A diffusing disc 7027 extends around theperimeter of apertures 7034 and also apertures 7029. It should be notedthat a diffusion disc such as 7027 could be manufactured with a barriersplitting said disc 7027 along a plane parallel with rotating discs 7030and 7028. The assembled apparatus shown in FIG. 7 is also provided withan enclosing cover 7010 which encloses a space around and close toparallel discs 7030 and 7028. Enclosure 7010 is provided with a conduit7012 which can transfer fluids there through in the direction shown byarrow 7014. The purpose of the apparatus shown in FIG. 7 is to provide areliable and efficient means of manufacturing bio-diesel. A fat streamat a suitable pressure such as between 400 and 600 psi (pounds persquare inch) can be transferred in the direction shown by arrow 7000into conduit 7002. The catalysts (e.g., sodium hydroxide and/or L-CO₂,with water as required) and methanol and/or ethanol can be transferredunder pressure corresponding with the pressure of triglyceride fatstransferred through conduit 7002 and in the range of 400 to 600 psi.Parallel discs 7030 and 7028 are arranged in close proximity and withspace of between 100 and 200 microns, and an example of providing thespace is shown in section “X-X” where radial ridges 8010 and 8004 whichcorrespond with ridges 7019 and 7018 provide spaces such as 8008 and8002. In this way, triglyceride fats transferred through radial holessuch as 7034 and then through upper section through diffuser 7027 canpass between said discs 7030 and 7028. Correspondingly, fluidstransferred in the direction shown by arrow 7026 through conduit 7024 inshaft 7022 and then through annular apertures such as 7029 and thenthrough the lower segment of diffuser 7027 can also transfer into spacebetween rotating discs 7030 and 7028 at a controlled rate. Fluidstransferred through conduit 7002 can, in this way, travel through aradial space parallel with disc 7030 and toward the perimeter thereof.Fluids pumped at a controlled rate in the direction shown by arrow 7026also communicate with conduit 7024 and radial apertures such as 7029 andinto the space between discs 7030 and 7028. Therefore, in this wayfluids transferred through conduit 7002 contact fluids transferredthrough conduit 7024 between said discs 7030 and 7028 first coming intocontact after passing through diffuser ring 7027 and into said annularspace between discs 7030 and 7028. Therefore, in this way fluidstransferred through 7002 come into intimate contact with fluidstransferred through 7026 in the annular space between said discs 7030and 7028. Disc 7030 can be driven in the direction shown by arrow 7008at a speed of, for example, between 5000 and 15000 rpm while disc 7028can be driven in the direction shown by arrows 7009 and in the oppositedirection of arrow 7008. Fluids passing between said rotating discs 7030and 7028 are thereby exposed to very high shear. Furthermore, fluidsbecome mixed continuously at high speed and are unable to stratify orescape the high shear and severe blending conditions between said discs7030 and 7028. Conduit 7012 can be connected directly with a suitablevalve and pumping arrangement with flow regulators maintaining asuitable pressure in the space between rotating discs 7030 and 7028 andenclosure 7010. Fluids therefore are able to react during the time theyare enclosed between said rotating discs and before transferring intothe enclosed space within enclosure 7010 through radial slots such as7036. Said discs 7030 and 7028 can be held together by mechanicalpressure with contact restricted by ridges such as 7019 and 7018. Theapparatus shown in FIG. 7 can be arranged with multiple pairs of discscorresponding with multiple parallel rows of apertures such as 7034 and7029. In this way, manifolds may be arranged, for example, within boss7006 and 7020 such that streams of materials and fluids can betransferred between each pair of plates such that a quantity of fluidtransferred through conduit 7002 will be transferred into the spacebetween each pair of discs and correspondingly fluids transferredthrough conduit 7024 can also be transferred between each set ofrotating discs in a similar fashion to the description herein such thatfluids from conduit 7002 come into intimate contact with fluidstransferred through conduit 7024 and are then subjected to high shear asthe fluids are pumped through the space between each set of plates.

Referring again to FIG. 7 and the disclosure above, the apparatus showncan be used to produce bio-diesel and any other fluid derived fromingredients that may or may not mix well together. The purpose of thisapparatus is to ensure thorough mixing of fluids in proportionatequantities as required or desired by the reactions to facilitate thebringing together of all components needed for a particular reaction ona “micro” scale.

Referring now to FIG. 8, an organic chemical reaction is shown withtriglyceride and methanol molecules shown in proportionate quantities tothe left of the arrow pointing toward the resultant organic chemicals ofthe reaction, one fatty ester molecule and one glycerol molecule. As canbe seen for each triglyceride molecule, three molecules of methanol arerequired to produce a single fatty ester molecule and a single glycerolmolecule.

Referring now to FIG. 9, an apparatus is shown in a three dimensionalcross sectional view. The apparatus shown in FIG. 9 is intended for usein the production of fatty esters or bio-diesel and glycerol from rawmaterials comprising, for example, clean, filtered beef fat or tallowelevated in temperatures such that its flow characteristics are asneeded to efficiently facilitate blending with methanol and/or ethanoland a catalyst such as sodium hydroxide, potassium hydroxide, but mostpreferably, CO₂ which may be used either as a sub-critical or insuper-critical fluid phase. The apparatus comprises a series ofconcentric members wherein a conduit 9024 with liquid transferred therethrough in the direction shown by arrow 9022 is fitted with a flangesection having a substantially flat face. In diametrically opposingposition, a similar member comprising conduit wall 9076 with conduit9078 is arranged to retain flange portion with center line 9023 commonto both members 9076 and 9025. Conduits (not shown) are sealinglyattached to each member 9025 and 9076 such that fluid at a selectedtemperature and pressure can be transferred in the direction shown byarrows 9022 and 9080. Enclosing members 9025 and 9076, a pair of members9027 and 9086 with spaces 9014, 9094, 9068 and 9036 are concentricallyarranged such that the inner surface profile of said members 9027 and9076, when in operating position as shown in FIG. 9, generally followsthe outer profile of members 9025 and 9076. Enclosing members 9027 and9086, outer housing members 9028 and 9016 are arranged with spaces 9008,9092, 9062, 9037 and 9013, such that there is no contact between theouter members 9028 and 9090 with inner members 9086 and 9027. Theapparatus in FIG. 9 generally comprises three pairs of opposing members,each pair retaining pressurized fluids. Cross section “A-A” (A) shows across sectional profile of the contacting surfaces of members 9027 and9072. As can be seen, member 9027 is arranged with radially extendingridges 9900 and 9902 with spaces 9904 and 9906, for example, so that thecontacting ridges such as 9900 and 9902 press against the parallel innerflat surface 9910 of member 9908. Member 9908 of section “A-A”corresponds with member 9072, and member 9912 in section “A-A”corresponds with member 9027. Each pair of members such as 9025 and 9076are separately and independently mounted to driving means such that, forexample, member 9076 can be activated so as to apply pressure in thedirection shown by arrow 9080 at which time, member 9025 can be held inrigid disposition. Similarly, member 9908 can be compressed towardmember 9912, thereby applying a controlled pressure to the face ofridges such as 9900 and 9901. Applying pressure in this way can causegeneration of heat through friction when member such as 9908 is rotatedin the direction shown by arrow 9909, either when member 9912 is heldstationary or, alternatively, member 9912 can be rotated in thedirection shown by arrow 9903, by any suitable independent drivingmeans. Each pair of members such as 9025 and 9076 or 9072 and 9027 canbe rotated by variable speed driving means such that any suitable speedof rotation can be arranged. In operation, manifolds are provided totransfer pressurized fluids to each space between the concentricmembers, for example, members 9025 and 9027 and members 9027 and 9028can be arranged to transfer pressurized fluid in spaces 9026, 9037,9014, 9013, and/or 9024 in the direction shown by arrows 9022, 9020 and9018. Additionally, fluids can be transferred from any suitable sourcevia a suitable manifold arranged to transfer said fluid into conduit9078 in the direction shown by arrow 9080 or in the direction shown byarrow 9084 into space 9094 and, in doing so, provide streams of fluidthat will follow the internal profile of member 9086 and the outerprofile of member 9076 through spaces 9094 and 9068 and then in thedirection shown by arrows 9097 and 9066. Similarly, fluid transferredinto conduits 9024 and 9078 in the direction shown by arrows 9022 and9080, respectively, will follow the internal contour of conduits 9078and 9024 in the direction shown by arrows 9080 and 9022, respectively.Said fluid transferred into the central conduits 9024 and 9078 cantransfer through spaces 9096 and 9032 radially extending outward andaway from center line 9023 and into space such as 9010. Fluidstransferred via 9014 in the direction shown by arrow 9020 and into space9094 in the direction shown by arrow 9084 can contact with other fluidstransferred in the direction shown by, for example, arrows 9012, 9034,9066 and 9097 and can reach the annular space 9010 immediately prior totransfer through annular space such as 9102 in a radially outwardextending direction, as shown by arrow 9040. In this way, fluids such asbeef fat having been suitably refined and transferred through radialspaces 9096 and 9032 in the direction shown by, for example, arrow 9030can be encapsulated or sandwiched within a fluid, such as super-criticalCO₂, transferred through, for example, spaces 9014 and 9094 in thedirection shown by arrows 9012 and 9034. Fluids transferred throughconduits and spaces such as 9094, 9014, 9026, 9036 and 9068 can beheated as a consequence of friction between the faces enclosing spacessuch as 9096 and 9032 by rotating members 9076 and 9025 in opposingdirections and/or by applying pressure simultaneously in the directionshown by arrows 9080 and 9022, whereby heat is generated in directproportion to the energy spent in compressing the members together whilerotating. In this way, sub-critical liquid CO₂ transferred through aspace such as 9014 can be heated to, for example, above 100° F.,therefore, causing super-critical phase to occur. Fluid transferred inthe direction shown by arrow 9018 through space 9013, or alternativelythrough conduit 9110 in the direction shown by arrow 9108 and throughspace 9050 in the direction shown by arrow 9052 can be arranged toreduce the combined temperature of fluid transferred from annular space9010 through 9056 in the direction shown by arrow 9040. The profile ofeach member can be arranged to create restriction or provide more spacefor fluids being transferred under suitable pressure through eachannular space. Temperature can be controlled by either developing heatthrough friction as described above or the temperature of any fluid canbe reduced when combined with a fluid of a lower temperature transferredin controlled mass flow via space 9050 in the direction shown by arrow9052. Fluids transferred through space 9013 in the direction shown byarrows 9006 and 9002 may be combined with fluids transferred throughconduit 9106 and conduit 9048 prior to contacting fluids transferredthrough spaces 9102 and 9056 in the direction shown by arrows 9012 and9040, respectively, at a confluence with fluids transferred through 9004in the direction shown by arrow 9014. With the apparatus as shown inFIG. 9, all fluids may be transferred, ultimately into conduits 9078,9094, 9014, 9013 and 9106 and combined in layers which can be thoroughlyblended by the rotating of members such as 9086 or 9090 in opposingrelative directions. In each case where opposing faces provide spacethrough which fluids can be transferred, the respective members can bearranged to apply pressure and to generate heat which can be preciselycontrolled so as to suit a particular reaction. In this instance, such amethod of generating a controlled quantity of heat can be used toconvert sub-critical liquid CO₂ to a super-critical phase, therebyinducing the aggressive solvent property of super-critical CO₂ which canthen be blended with, for example, beef or plant oils such that whensuch mixture is added to a controlled quantity of methanol and/orethanol, bio-diesel and glycerol can be produced. The apparatus shown inFIG. 9 indicates several conduit spaces which can provide for blendingof up to six or more fluids together. However, in the production ofbio-diesel, the fluids typically include a proportionately controlledblend of liquid CO₂ and beef fat maintained at a temperature such thatboth are in fluid state, which is then combined with liquid methanoland/or ethanol. Catalyst sodium hydroxide or similar optionally can beeliminated.

The apparatus shown in FIG. 9 is arranged such that the distance betweenthe opposing faces, each side of spaces 9032 and 9097 will mostpreferably be on the order of 0.004″ or 100 microns and similarly,spaces at 9056 and 9102 defined by parallel surfaces of faces such as9912 and 9908 shown in section “A-A” (A) can also be arranged at adistance of 100 microns between the faces. The distance between radialridges such as 9902 and 9900 can be as much as 1.0″, however, apreferred dimension for distance B as shown in section “A-A” (A) will be200 microns. Ridges such as 9900 and 9902 as shown in section “A-A” (A)allow fluid to be transferred through spaces 9904 and 9906. When member9912 is rotated in a direction such as shown by arrow 9903, opposite tothe direction of member 9908 shown by arrow 9909, fluid transferredthrough spaces 9904 and 9906 can be thoroughly blended while controlledheat generated by friction at the ridges such as 9900 and 9902 can beadvantageous to the reaction of fluids in said spaces. For example, beeffat or oil is not miscible with methanol and, in fact, the fluids ofmethanol and beef fat tend to separate, therefore, providing a difficultcondition for reaction between methanol and beef fat. However, byproportionately controlling a mixture comprising measured quantities offluid beef fat, methanol and CO₂, the rotating action of member 9912against member 9908, results in the transfer of fluid in 9906 betweenthe face of ridge 9902 and member 9908 and thereby subjecting this fluidto extreme pressure. Also, fluid in space 9904 is transferred via theminute space between 9900 and the flat face of member 9908. Fluidtransferred between said spaces is similar in volume across the face ofall ridges such as 9900 and 9902 and this action can provide anaggressive mixing action for fluids being transferred through spacessuch as 9904 and 9906. Furthermore, long carbon chain molecules such astriglycerides can be stretched or contorted while transferring throughthe narrow spaces between a ridge such as 9900 and a face, such as 9908.

Referring again to FIG. 9 and, in particular, section “A-A” (B), ridges9932 and 9930 are shown with a wedge profile such that gaps 9931 and9937 enables fluid transfer via space 9934 and 9936 to be forced intosaid gaps 9937 and 9931 and compressed such that any large moleculessuch as triglycerides can be stretched or, alternatively, any fluidstransferred through spaces such as 9934 and 9936 are thoroughly blendedwhen rotating member 9942 is rotated in the opposite direction to thearrow 9934 against the stationary member 9938 or, alternatively, whenmember 9938 rotates in the direction opposite to the direction shown byarrow 9939. Section “A-A” (B) shows the alternative profile ridges,however, other aspects are similar to those of section “A-A” (A). Moreparticularly, spaces 9934 and 9936 are exemplary and representative ofall such spaces provide along the radial band following a path whereinmember 9072 and member 9027 are held together under pressure and wherecontact between the two members occurs only at the ridges such as 9930and 9932. In this way, high pressure, such as 10,000 lbs per square,inch can be applied to the points of contact between said member 9942and member 9938 of section “A-A” (B).

Referring now to FIG. 10, a cross section through an apparatus similarto the apparatus disclosed above in association with FIG. 9 is shown.Outer housing at 10024 is provided to enclose a series of rotatingmembers including 10020, 10004 and 10100. Each member such as 10024 isconnected directly to a rotating means and conduit which enables thepressurized temperature controlled transfer of fluids in the directionshown by arrows 10180 and 10012 and through channel provided by spacessuch as 10164 and 10040. Fluids transferred between members 10020 and10024 follow a conduit outwardly in the direction shown by arrows 10176and 10036. The plan shows a circular profile to the apparatus shown inFIG. 10 and the members 10004 and 10100 can be rotated at any selectedspeed and in opposite directions such that fluid transferred intoconduit such as 10016 are transferred through the conduit 10016 and inthe direction shown by arrows 10184, 10008, 10172 and 10028. Member10100 is fixed rigidly to a driving means and is located in appositedisposition to member 10004 and can be rotated about a common centerline 10000 which is common with member 10004. Cross section “X-X” showsthe end view of a segment shown by line X-X and tapered rollers 10268,10208, 10212 and 10236 are held captive in recesses of member 10220 withradial channels 10200, 10204, 10216 and 10228, radiating from centerline 10000 which connects directly with channel 10016. In the uppermember 10228, which corresponds with member 10020 in opposing member10244 which corresponds with member 10091, members 10020 and 10091rotate in opposite directions as shown by arrows 10224, member 10244 and10248 in section “X-X”. Member 10244, which corresponds with rotatingmember 10091 is shown with radiating channels 10264, 10256, 10252 and10240 radiating from center line 10000 and communicating directly withchannel 10096. Rollers 10268, 10208, 10212 and 10236, shown in section“X-X” are arranged to be retained by recesses in member 10220 and heldagainst opposing flat inner surface of member 10244. Therefore, asmember 10220 rotates in the direction shown by arrow 10224, member 10244may be held stationary or rotate in the direction shown by arrow 10248.Under these conditions, rollers such as 10268 and 10208 are rotated in aclockwise direction when viewed as shown in section “X-X”. It can beseen that fluid transferred through conduit 10016 in the direction shownby arrows 10184, 10008, 10172 and 10028 after passing through microconduits such as 10044 and 10160, the channel shown as 10232 in section“X-X” will enable the direct transfer of said fluid transferred throughconduit 10016 and into space around tapered rollers such as 10268 and10208. Conversely, fluid transferred through conduit 10096 in thedirection shown by arrows 10112, 10108, 10092 and 10120 will communicatevia micro channels 10076 and 10132 and as shown in section “X-X”. Aftertransfer through micro conduit such as 10264 and 10256 in member 10244,the fluid having been transferred most preferably under selectedpressure and at a selected temperature via conduit 10096 will contacttapered rollers such as 10268, 10208 and 10236 in section “X-X”. It canbe seen, therefore, that when a selected first fluid such as methanol istransferred through, for example, conduit 10096 in the direction shownby arrow 10108 and a second beef tallow fluid is transferred via conduit10016 in the direction shown by arrows 10008 and 10028, both first andsecond fluids can meet and contact around the space between rollers suchas 10268 and 10208 and the recesses in member 10220 retaining saidtapered rollers under temperature and pressure control, when the secondfluid has rate of mass flow proportionate to said first fluidtransferred through conduit 10096. The two fluids will make contact witheach other as rollers 10268 and 10236, for example, are rotated in aclockwise direction when viewed according to section “X-X”. Furthermore,pressure can be applied to both members 10020 and 10091 in the directionshown by arrows 10184 and 10012 and controlled pressure can also beapplied to member 10091. The only point of contact between members 10091and 10020 is via said tapered rollers such as 10268 and 10236. Saidpressure applied via said roller such as 10268 can be controlled so asto provide a most efficient process such that when said first and secondfluids are in contact in space around roller such as 10268, pressureapplied to members 10020 and 10091 is applied to the blended first andsecond fluids also. The rate of mass flow of said first and secondfluids, the pressure applied via members 10020 and 10091 and therotational speed of member 10020, corresponding with member 10220, inthe direction shown by arrow 10224 against member 10091, correspondingwith member 10244, rotating in the direction shown by arrow 10248 can becontrolled at any suitable speed, but most preferably, on the order of1,000-2,000 rpm or, alternatively, up to 10,000 rpm or more or less.FIG. 10 shows that fluid can also be transferred in the direction shownby arrows 10180, 10012, 10176 and 10036 continuing in the directionshown by arrows 10156 and 10048 via channel 10052 so as to blend withfluid transferred through conduit 10060 in the direction shown by arrow10056 and conduit 10152 in the direction shown by arrow 10148. Fluidtransferred in this way can combine and collectively travel in thedirection shown by arrow such as 10068 and 10140 so as to then blendwith combined fluids transferred via conduits 10016 and 10096 in conduit10124 and 10084. Finally, the combined fluids transferred into theapparatus shown in FIG. 10 can be transferred via conduit 10124 and10084 in the direction shown by arrows 10116 and 10104.

Referring again to FIG. 10, most preferably the apparatus can be used toproduce bio-diesel at a high rate of production by ensuring the correctand thorough blending of immiscible fluids, such as methanol and fluidbeef tallow or oil. The method described in association with FIG. 10provides a series of radially located rollers such as shown in section“X-X”, rollers 10268, 10208, 10212 and 10236. Any convenient quantity ofradially located rollers similar to those shown in section “X-X” can beprovided around the full annular band created by the contact point ofall rollers rotating in recesses such as shown by rollers 10268, 10208,10212 and 10236 in section “X-X”. All rollers can be fitted and retainedby recesses in a first member such as 10220 so as to rotate and rollacross the annular band that said rollers can contact. Said first member10220 may rotate in the direction shown by arrow 10224 in opposingdisposition to said second member 10244 rotating in the direction shownby arrow 10248 and said members 10020 and 10091 may be held underpressure so as to clamp said rollers such as 10268 and 10236 shown insection “X-X”. Fluid transferred via radial micro conduit such as 10200and 10264 can be blended thoroughly by the action of said rollers suchas 10268 in the confinement of the space between the respectivecomponents including member 10220 and opposing member 10244 which applypressure to fluids as they are blended by transfer through therespective micro conduits such as 10268 in member 10244 and via microconduit such as 10204 in member 10220 of section “X-X”. Furthermore, itshould be noted that when large molecules of organic compounds such astriglycerides are provided under fluid pressure in the manner describedherein above then subjected to confinement between hardened taperedrollers such as 10268 in section “X-X”, the molecules can be stretchedand when in a stretched condition are more likely to react with otherelements or compounds such as methanol or ethanol.

The apparatus described in association with FIG. 10 (and FIG. 9)provides a series of annular conduits through which miscible orimmiscible fluids can be transferred for the purpose of blendingtogether in a confined space. When blending such immiscible or misciblefluids in a confined space and subjecting the fluids to an intensemixing action, the desired reaction can occur rapidly and within theconfinement of the space provided. After transferring into the confinedspace around rollers such as 10268 and 10236, etcetera and beingsubjected to intense blending action facilitated by the confinedrollers, a more complete reaction between the fluid compounds can occur.Referring again to FIG. 10, it should be noted that the fluidstransferred through the annular passageway shown are provided undercontrolled pressure at a selected temperature and each annular conduitis separated from adjacent annular conduits by manifold attachmentsprovided with suitable seals and bearings. Pressure provided via memberssuch as 10004 and 10100 rotating in the opposing direction shown byarrows such as 10008 and 10108 can be provided by hydraulic piston andsuitable retaining sleeve. The hydraulic liquid of the piston may be thefluid being transferred. A suitable screw and thread arrangement can beprovided such that when a selected pressure has been facilitated, a locknut can be arranged to fix the desired pressure for the duration of theproduction run.

Referring again to FIG. 10, the preferred embodiment is shown in theapparatus and according to the disclosure above provides a means ofproducing bio-diesel and glycerol from, for example, beef fat andmethanol using liquid phase or super critical CO₂ as the catalyst,enabling reaction between the triglycerides of the beef fat and methanoland/or ethanol. The reaction occurring is as shown in FIG. 8 whereinthree methanol molecules and a single triglyceride molecule react toproduce a mixture of fatty esters and a single glycerol molecule. Thevolume of bio-diesel (fatty esters) produced is approximately 10 timesthe volume of glycerol produced when manufactured with apparatus similarto that shown in FIG. 10 (or FIG. 9) and, in particular, when CO₂ isused as catalyst. The requirement of washing with large quantities ofwater to separate any sodium hydroxide or potassium hydroxide, catalystmay be eliminated. More particularly, when using the apparatus describedin FIG. 10, the production process is much more rapid, does not requirelarge quantities of water and any remaining CO₂ catalyst evaporates whenexposed to ambient conditions.

In another preferred embodiment, bio-diesel and glycerol produced in themanner described in association with FIG. 10 can be processed so as tocrystallize glycerol and fatty esters by lowering the temperature tobelow the freezing point of these two products. More particularly, amixture of glycerol fatty esters (bio-diesel) and L-CO₂ can betransferred through a similar aperture or nozzle into an expansionchamber wherein the pressure drop across the nozzle is sufficient tofreeze the glycerol and bio-diesel, thereby causing it to crystallizewhile maintaining the majority of the CO₂ in liquid phase. For example,a pressure drop from 500 psia down to 350 psia will reduce thetemperature well below the crystallizing point of bio-diesel andglycerol. A resultant blend of crystallized glycerol, crystallizedbio-diesel and L-CO₂ can then be transferred to a suitable separationapparatus. The blend of crystallized glycerol and bio-diesel with L-CO₂can be separated by centrifuging in an enclosed pressurized decanterstyle centrifuge. The density of glycerol is 78 lbs per cu.ft., whilethe density of bio-diesel is 58 lbs per cu.ft. The density of L-CO₂ canbe adjusted such that bio-diesel will float and glycerol will sink undernormal gravitational conditions. However, when transfered in continuousstream through a centrifuge separator, the solid, crystallized glycerolcan be readily separated from the L-CO₂ and crystallized bio-diesel.Subsequently, the L-CO₂ can be separated from the crystallizedbio-diesel. Any moisture present will be evaporated during the processand the crystallized bio-diesel can then be heated until liquid phase isreached. In this way, glycerol of high quality without impurities can bemanufactured when using CO₂ in either liquid or dense vapor phase as theseparating medium and catalyst.

Referring to FIGS. 1 through 5 and FIGS. 7 and 9 through 10, two sets ofapparatus for the production of bio-diesel are disclosed. The purpose ofthis apparatus is to provide effective and efficient manufacture ofbio-diesel and glycerol with equipment of substantially reduced physicaldimensions when compared to typical bio-diesel plants currently in use.

Following the production of bio-diesel and glycerol in a singlecontinuous stream emanating from conduit 7012 in FIG. 7 and manifolds7000 and 4088 in FIG. 1, it may be desirable to separate bio-diesel fromthe mixture of components in a single stream and to ensure that it canbe cleaned and then isolated in storage vessels prior to use as a fuel;also glycerol can be separated from the stream and isolated in separatestorage.

The following lists properties of the preferred components involved inthe production of bio-diesel and glycerol according to the abovedisclosures;

Specific Gravity Chart

Matter Process (and Abbreviated Temperature Approximate Solid or LiquidDensity Item Identifying Mark) Range Melting Point (@31° F.) Lbs/cu′ 1Glycerol >29°–>90° F.   18° C. Solid 78 2 Methanol >29°–>90° F. −65° C.Liquid 49 3 Liquid Carbon Dioxide >29°–>90° F. −57° C. Liquid 58 (L-CO₂)4 Water (H₂O) >29°–>90° F.    0° C. Solid 62 5 Bio-diesel >29°–>90° F.  20° C. Solid 58 6 Tallow (Beef fat) >29°–>90° F. Solid 55

The Specific Gravity chart above lists six preferred componentsassociated with the reaction to produce bio-diesel as disclosed herein.The approximate melting point of each component is also shown with thetemperature range of the reaction. The reaction as proposed betweenmethanol and triglycerides produces glycerol and bio-diesel in a singlestream and it is therefore desirable to separate the components of theresultant stream prior to using the products after manufacture. Adecanter style centrifuge has the capacity to separate crystallizedglycerol from the bio-diesel by using the correct style of decantercentrifuge which should be enclosed and able to withstand a pressure ofapproximately 500 psi. The blend may be continuously transferred intothe decanter style centrifuge. Crystallized glycerol with a specificdensity of 78 lbs/cu.ft. is the most dense of the six materials listedin the above table (assuming all six components are present; it shouldbe noted that the quantity of the methanol component can besubstantially reduced when L-CO₂ is present and used as the catalyst andcarrier or medium and the micro apparatus utilizing reaction conduits ofapproximate dimension 100 microns×200 microns or less or more),therefore methanol would be the first material to separate and settleagainst the inner surface of the rotating bowl of the centrifuge. Theentire stream of fluids can be transferred through a restriction in theconduit through which it is flowing such that the controlled pressuredrop across the restriction is sufficient to cause a temperature drop asrequired to solidify any component contained within the stream, asdesired. For example, assuming that the temperature of the stream isabout 75-80° F. and at a pressure of about 1,100 psi immediately afterthe reactions are complete, the stream could be transferred through asmall orifice of suitable size such as 0.125″ diameter to about 0.25″diameter thereby causing a substantial reduction of temperature; andwhen the temperature drops to <18° C., all glycerol will solidify andthe smaller the orifice is, the smaller will be the crystals ofglycerol. Transferring said stream through a small aperture, therebyfacilitating a significant pressure drop, into a vessel of sufficientvolume (or comparable conduit), controlled at about 500 psi will ensuresmaller crystals are formed as the selected pressure drop enablescrystals of the selected component to solidify. The pressure drop could,for example, be arranged to occur as the stream is transferred into adecanter style or other suitable centrifuge. Bio-diesel is alsocrystallized at the lower end of the proposed temperature range and witha specific gravity of 58 lbs/cu.ft. can float on L-CO₂ when the pressurein the centrifuge is elevated to 600 psi. Therefore a procedure can befollowed whereby in a first pass through a decanter style centrifuge,pressure can be held at an elevated pressure, say of approximately 600psi and 34° F. when only the glycerol and water of the above sixcomponents will separate out and fall away from the center of thecentrifuge and be held against the inner wall of the centrifuge therebyenabling separation with a standard screw conveyor. Glycerol can then bewashed with an adequate quantity of water sprayed into the outer beachregion of a decanter style centrifuge through which the glycerol istransferred. In this way, glycerol can be thoroughly washed withoutrequiring copious quantities of water. The remaining fluid transferredfrom the first centrifuge pass, which may contain methanol, L-CO₂ andbio-diesel, can be transferred to a second or third decanter stylecentrifuge operating at an internal pressure of approximately 600 psiand a temperature of 30° F. In this case, bio-diesel will be theheaviest, or that component with the highest specific gravity, and willtherefore settle against the inner wall of the centrifuge bowl, enablingremoval by the conveyor (Archimedes screw). Methanol will accumulate asthe inner most layer in the concentric layers of the operating decanterstyle centrifuge. A dam or weir at an end of the centrifuge can beprovided to enable the removal of liquid methanol which has a very lowfreezing point and will therefore remain liquid during this process at30° F. Finally, L-CO₂ can be boiled off to atmosphere, or alternativelyfiltered and recycled.

Referring again the Specific Gravity Chart, a list of six componentsrepresenting components that may be present during the production ofbio-diesel is provided. However, the process is not limited to justthese six components. Solid catalysts such as silica may be used in abio-diesel production process, for example, and other catalysts are alsoappropriate for use as long as they can either be fixed to the innersurface of the process reaction tubes (see above) or alternativelyprovided as a suspension or solution blended with the stream ofcomponents.

Referring now to FIG. 11, a diagram comprising a series of rectangleswith connective arrows shows steps in a production configuration thatcan be arranged to produce bio-diesel and other components of a chemicalreaction that uses plant matter as a source of triglycerides to producebio-diesel. Rectangle 11002 represents an apparatus capable of grinding,chopping or generally cutting a stream of plant matter into very smallpieces which can then be pulverized in equipment 11006 wherein atransfer conduit 11004 can be arranged to automatically transfer theprocessed plant matter to pulverizer 11006. Conduit 11008 transfers thepulverized plant matter to a pumping station 11010 wherein a selectedquantity of the pulverized plant material is compressed into a conduitby way of a reciprocating piston with connecting rod attached to a crankshaft (not shown in detail) wherein said crank shaft revolves at asuitable speed, thereby providing a reciprocating piston action suchthat said piston compresses a quantity of pulverized plant matter intosaid conduit followed by the opening of a space in said conduit,allowing a subsequent quantity of pulverized plant matter to betransferred therein which is then also compressed against the plantmaterial having been compressed in the immediate earlier compressionstroke of said reciprocating piston.

In this way, plant matter can be progressively transferred fromapparatus 11002 through said conduit 11004 in a tightly compactedcondition, then pulverized in enclosed apparatus 11006 and pumpedthrough conduit 11008 and combined with L-CO₂ transferred from storagesource vessel 11003 through conduit 11005. The blended stream of plantmatter and L-CO₂ is then transferred via high pressure pump 11010 at acontrolled temperature above 87.87° F. and higher than the criticalpressure 1070 psia. Said first conduit inhibits the escape of L-CO₂ fromsaid second conduit due to the tightly compacted condition of the plantmatter sealing any pathway there through. In this way, pulverized plantmatter can be mixed with L-CO₂ to provide a mix of L-CO₂ and pulverizedplant matter in a continuous stream transferred under a selectedpressure and temperature. Said homogenous blend of pulverized plantmatter and L-CO₂ may also be transferred from said second conduit into athird conduit via a check valve. Said blend of pulverized plant matterand L-CO₂ can then be transferred through said third conduit and heatedto a temperature by way of one or more band heaters provided in tightcontact around said third conduit, thereby also elevating thetemperature of the combined blend of L-CO₂ and pulverized plant matterto a pressure and temperature above the minimum threshold forsuper-critical CO₂, thereby causing a phase change of said L-CO₂ tosuper-critical condition. In this way, plant matter having beenpulverized and then blended with L-CO₂ can be compressed together withsuper-critical phase CO₂. In this way, any fats or oils contained in thepulverized plant matter can be separated in a miscible blend withsuper-critical CO₂.

Referring again to FIG. 11, compressor 11010 elevates the pressure ofsaid blended stream of L-CO₂ and pulverized plant matter such that L-CO₂changes phase to a stream of super-critical phase which can then betransferred through high pressure conduit 11011 to centrifuge 11013where liquefied oil can be removed from the pulverized plant matter andtransferred through a high pressure conduit 11011 to centrifuge 11013.

Centrifuge 11013 shall most preferably be a vertically disposed decanterstyle and built in such a manner that the pressure exerted internally bythe expanding force exerted by super-critical CO₂ will be safelycontained. Centrifuge 11013 can be provided with at least two extractionports through which a first stream extraction port oil separated fromsaid pulverized plant matter can be extracted in the direction shown byarrow 11012 and a second stream of pulverized plant matter extracted istransferred via a second conduit 11014 to storage container 11020. Oiltransferred via conduit 11012 is blended with L-CO₂ and a quantity ofmethanol equal to about 5% of the total volume, and the combinedmaterials are blended and heated in vessel 11016. Blended materialscomprising super-critical phase CO₂ and methanol are blended with oilextracted from said pulverized plant matter and the temperature andpressure of the combined blend of materials are elevated toapproximately 250° F. and 150 atmospheres.

Referring again to FIG. 11, in another preferred embodiment, the methodof grinding and, most preferably, liquidizing any suitable plant matter,such as rapeseed involves the entire plant in the process, but in anyevent, those parts of the plant which yield the highest ratio of oil.The liquidized plant matter is then pressurized to a selected pressuresuch as above the lowest temperature at which CO₂ can exist insuper-critical phase. Most specifically, the liquidized plant matter canbe blended with super-critical phase CO₂ and thoroughly agitated untilall oil formerly contained within plant cells has been extracted andseparated from the source cellular repository. The most suitablepressure at which CO₂ will exist in super-critical phase or abovecritical pressure is 1069.96 psia and the minimum temperature at whichCO₂ will exist in critical phase is 87.87° F. Therefore, in order toprovide the aggressive solvent properties required to extract oil fromplant matter, super-critical phase CO₂, being an aggressive solvent, ismost suitable for this purpose. In another preferred embodiment, plantmatter may be shredded and processed by transferring through a grindersuch as a Moyno® grinder pump and, in particular, with the employment ofa Moyno® annihilator and/or a Moyno® pipeliner which has been designedand developed for industrial applications in food processing such as theprocessing of vegetable and fruit waste, paper and stock waste, poultrywaste, and corn kernel. Additionally, it may be beneficial to installmore than one grinder pump in series along the same conduit. Bailedplant matter can be stuffed into a Moyno® pump of any suitable designusing, for example, the Moyno® 2000HS system such that the plant matter,whether dry or still wet after recent harvest, can be handled with suchequipment as is manufactured by Moyno® and then pumped continuouslythrough Moyno® grinders. Most importantly, plant matter can be processedand handled most readily when in a fluid condition; therefore, afterprocessing the plant matter with the use of Moyno® grinders as describedabove, L-CO₂ can be blended with the finely ground plant matter to forma single continuous stream of plant matter and L-CO₂. The continuousstream can then be processed further by way of transferring through asuitable centrifuge as designed and manufactured by American BeefProcessing, LLC of Clackamas, Oreg. Equipment can be obtained fromeither Moyno® or American Beef Processing, LLC at 15501 SE PiazzaAvenue, Clackamas, Oreg. 97015.

A stream of processed plant matter and L-CO₂ can be transferred througha centrifuge so as to separate all solid matter in a single streamextracted from the fat and the extracted oil will be removed during thecentrifugal process at suitable rate, such as 30,000 pounds per hour.

An alternative method of separation to the centrifugal method proposedherein can be by way of a stratification separation column wherein thestream of L-CO₂, oil and remaining solid plant matter is transferred inan enclosed conduit to a suitable column, most preferably manufacturedfrom either stainless steel such as 316 or carbon steel, and allowed tostratify therein. The stratification process enables each component ofthe processed stream such as plant oil (corn oil) or any oil extractedfrom any suitable source, but most preferably, in this instance, plantmatter, to be separated into layers of stratified material. For example,oil having a specific gravity of approximately 55 lbs/cu.ft. canstratify above water having a specific gravity of 62.4 lbs/cu.ft. Solidplant matter and, in particular, the cellulose cell walls having adifferent specific gravity, will also stratify. L-CO₂ has a specificgravity of approximately 29 lbs/cu.ft. when retained in super-criticalphase and, therefore, being the lightest component separated at thestratification pressure vessel, will stratify and float to the upperlevels in the column.

Recently an improved method of producing bio-diesel from plant matterhas evolved incorporating the use of super-critical methanol undertreatment conditions of 350° C. and 43 MPa, however, while the reactiontime has been reduced, it remains difficult to apply due to the highcost of pressure vessels large enough to contain the reacting materialsfor the duration of the reaction time. Furthermore, a temperature of350° C. is too high to the extent that plant matter will decomposereadily at this temperature and contaminants will be produced inquantities too large to prevent the deleterious consequences ofdecomposing plant matter at 350° C. The method disclosed herein employsthe benefit of lowering the temperature at which a blend of methanolwith sufficient CO₂ will enter super-critical phase.

Additionally, the extraction of oil from plants can be achieved asdescribed herein in association with FIG. 11 wherein super-criticalphase CO₂ is blended with a stream of pulverized plant matter. Theaggressive solvent properties of super-critical phase CO₂ rapidlyextracts any fat (triglycerides). Subsequent to the extraction oftriglycerides, a measured quantity of methanol and/or ethanol can beadded to the continuous stream of plant matter and CO₂ such that byelevating the pressure and temperature to approximately 250° C. and 2300psig, bio-diesel can be produced in a continuous stream bytransesterification of triglycerides extracted from the plant matter.Subsequently, the components of the continuous stream can be separatedin a suitable enclosed and pressurized centrifuge.

Referring now to FIG. 12, a diagram showing a preferred method ofbio-diesel and glycerol production is shown in plan view. The diagramshown in FIG. 12 shown as illustrative only and has not been drawn toscale. However, the apparatus for this preferred method of producingbio-diesel is shown in a convenient manner for the purpose ofexplanation. A stream of fatty adipose tissue sourced from beef cattleslaughtered, eviscerated, dressed and chilled for the purpose ofharvesting beef for human consumption is transferred via conduit 12000and into emulsifier 12002. The stream of fatty adipose tissue isharvested simultaneously with the production of a second stream of leanboneless beef using equipment manufactured by American Beef Processing,15501 SE Piazza Avenue, Clackamas, Oreg. The first and second streams ofboneless beef are produced in production quantities typically on theorder of approximately 50,000 lbs/hr for the lean stream and 35,000lbs/hr for the fatty adipose tissue stream. The ratio of the first andsecond streams can vary according to the lean content of the primarystream fed into the separation equipment. However, most commonly, 50'sor, in other words, a supply of boneless beef comprising 50% lean andapproximately 50% fat is most commonly used. The special apparatusmanufactured by American Beef Processing can be arranged to process moreor less than 100,000 lbs/hr and typically the mass flow ratio of thefatty adipose tissue stream will be on the order of 40,000 lbs/hr.Protein content within the fatty adipose tissue and lean beef attachedto the fatty adipose tissue can be removed by the method describedhereunder. The equipment operates according to the followingdescription.

Conduit 12000 is a fully enclosed conduit through which boneless beefcan be transferred under pressure and conduit 12000 is attached to theinlet manifold of an emulsifier such as is manufactured by Cozzini, Inc.Other manufacturers are also capable of building this equipment,however, the equipment manufactured by Cozzini, Inc. has been found tobe reliable and capable of processing adequate quantities in a givenproduction period. Furthermore, the fatty adipose tissue transferredunder pressure via conduit 12000 can be transferred safely, reliably andsubstantially without leaking such that the stream of fatty adiposetissue, when transferred into emulsifier 12002 at a rate ofapproximately 40,000 lbs/hr can be reliably emulsified, such that themaximum particle size does not exceed the maximum size that can bereliably and consistently processed by the equipment described inassociation with FIG. 12. The input stream 12000 to emulsifier 12002 isdesirably supplied at a mass flow rate of approximately 30,000 lbs/hr ormore or less, but at such a quantity as to enable the emulsification.After emulsification, the stream of emulsified fatty adipose tissue istransferred via an enclosed conduit 12004 to enclosed scraped surfaceheat exchanger 12006. Scraped surface heat exchanger 12006 can bemanufactured by Waukesha Cherry-Burrell in Wisconsin and the arrangementof heat exchangers shown in FIG. 12 includes three horizontally disposedconduits connected at each end to, firstly an inlet and secondly anoutlet, such that scraped surface heat exchanger 12006 is connecteddirectly to second scraped surface heat exchanger 12012 via conduit12008 and scraped surface heat exchanger 12010 is connected directly tothird scraped surface heat exchanger 12016 via conduit 12012. Said flowof emulsified fatty adipose tissue may be transferred via conduit 12004into a bank of scraped surface heat exchangers in a stream ofsubstantially consistent rate of flow, and after said stream of fattyadipose tissue has been processed therein, the temperature of the fattyadipose tissue extracted from said bank of scraped surface heatexchanger via conduit 12018 may be approximately 115° F. The bank ofheat exchangers may comprise any suitable number therein, however, inthe arrangement as shown in FIG. 12, a total of three separatehorizontally disposed scraped surface heat exchangers are shown. Thetemperature of said stream of processed fatty adipose tissue transferredvia conduit 12018 to pump 12022 should be greater than 108° F. and lessthan 120° F. It is a purpose of the apparatus shown in association withFIG. 12 to separate substantially all protein and solid matter such ascollagen connective tissue and/or cartilinageous bone from a stream ofclear, warm, filtered beef fat. The heated stream transferred into pump12022 is transferred under pressure via conduit 12020 to firstcentrifuge 12026. First centrifuge 12026 separates the stream of warmfatty adipose tissue into two components comprising a first stream ofclear, warm, filtered beef fat via conduit 12021 and into filter 12032.Said second stream of solids separated by means of first centrifuge12026 comprises all solid matter derived from the stream of heated fattyadipose tissue and is transferred via conduit 12028 directly to positivedisplacement pump 12029 and into enclosed conduit 12030 under suitablepressure. A stream of protein, connective tissue, cartilinageous boneand other semi-solid matter pumped under pressure via positivedisplacement pump 12029 is returned to apparatus not shown inassociation with FIG. 12, however, said stream of solids is blended withlean beef separated from said stream of 50's referred to above prior toretail packaging or further processing into beef patties or the like.

The stream of beef fat transferred via enclosed conduit 12021 andfiltered in filter 12032 prior to transfer into pump 12036 via conduit12034 is then blended with proportional quantities of methanol and/orethanol and a proportionate quantity of L-CO₂. The blend comprising beeffat, methanol and/or ethanol and L-CO₂ in suitable proportions ismaintained at a selected temperature and pressure of up to 250° C. and2250 psi for a period of time sufficient to facilitate the reactionbetween the three materials, such that bio-diesel or a mixture of fattyesters and glycerol is produced from the reaction shown in FIG. 8.

Methanol is provided from a source and transferred by positivedisplacement pump 12084 via conduit 12082 in the direction shown by thearrow and a relatively proportionate quantity of L-CO₂ is pumped bypositive displacement pump 12049 in the direction shown by the arrow viaconduit 12078. A blender which may be a continuous static blender 12048or any other suitable type of blender is provided as shown. Generally,the apparatus shown in FIG. 12 is arranged to provide three streams ofliquid matter each provided under suitable pressure such that thecombined stream will react according to the organic chemical reactionshown in FIG. 8. It is desirable in order to maximize efficiency of thereaction that the liquid materials be provided in measured quantities,precisely controlled, in a continuous stream. Temperature and pressureshould be maintained at optimum values in order to achieve the mostefficient production rate available. The combined stream may betransferred via one or more reactors each optionally containing anappropriate solid catalyst, if necessary, which should line the walls ofeach micro channel which are arranged in a series of parallel microconduits within micro reactor arrays 12040, 12032 or 12027. The blendedstream of liquid materials pumped via positive displacement pumps 12036,12049 and 12084 should be maintained at an optimum temperature andpressure of 250° C. or more or less and 2250 psig or more or less or atany other suitable temperature and pressure that will facilitate themost rapid and effective reaction between the three materials comprisingthe combined stream. Table #2 (FIG. 13) shows a range of temperaturesand pressures that can be maintained to achieve maximum efficiency ofthe reaction which is similar to the reaction shown in FIG. 8. Thestream of liquid comprising glycerol and a mixture of fatty esterstransferred via conduit 12030 to pump 12036 comprises residual methanoland CO₂ which is desirably extracted and disposed of by exhausting toatmosphere or, alternatively, recycling. However, in order to achievemaximum efficiencies, super-critical phase of methanol andsuper-critical phase of L-CO₂ is desirable during the reaction process.Pump 12036 controls the stream pressure such that it is continuouslytransferred into vessel 12041 via an orifice with a variable aperturesize. The entire stream of fluids can be transferred via the aperturewhich is located within vessel 12041 such that a drop in stream pressureoccurs as the fluids pass through said aperture. The cross sectionalarea of the aperture opening can be controlled and configured such thata pressure and substantial temperature drop occurs, causing certainfluids to crystallize. For example, the controlled pressure drop can bearranged such that glycerol is crystallized, thereby solidifying thefluids such that CO₂ will become gaseous and can be extracted fromvessel 12041 at a rate and mass flow-controlled extraction enabling aprecise control of pressure within said vessel 12041. CO₂ extracted inthis way can then be compressed and transferred through a suitable heatexchanger such that L-CO₂ can be transferred directly into a storagevessel and retained for subsequent recycling. The remaining fluids aretransferred via conduit 12060 and positive displacement pump 12062 intocentrifuge 12068 where glycerol having a specific gravity on the orderof 78 pounds per cubic foot is readily extracted when suspended in L-CO₂pressurized to approximately 500 psi and retained at approximately 32°F. L-CO₂ can be extracted and recycled and glycerol simultaneouslyextracted and transferred to a storage vessel and retained forsubsequent use. Said glycerol formed in this manner is a purest form ofglycerol devoid of contaminates such as sodium hydroxide which cannot beremoved entirely when manufactured by way of the commonly used orconventional bio-diesel production process using sodium hydroxide as acatalyst. Bio-diesel produced in this way comprises the majority of thefluids transferred into centrifuge 12068 and thereby extracted from thestream of fluids. Bio-diesel produced in this way is also of the purestkind and washing with water is not required since there are nocontaminates such as residual sodium hydroxide. Bio-diesel istransferred into suitable storage vessel, but most preferably, into roadand/or rail tankers for immediate shipping to customers. Bio-dieselproduced in this manner is the most suitable for use as an additive infossil fuel diesel. Federal legislation requires that sulfur beextracted from all fossil fuels, however, without lubricants that arepresently unavailable, fossil fuel diesel will be unsuitable for use inreciprocating diesel engines. It is therefore considered probable thatbio-diesel produced in accordance with the methods disclosed herein,shall be used as an additive in the amount of approximately 2% of thetotal mass weight of the fossil fuels produced subsequent to September2006. 2% bio-diesel produced in the manner herein disclosed providessufficient lubricity when added to the fossil fuels processed inaccordance with legislation.

The three components, CO₂, methanol (and/or ethanol) and triglycerides,will most preferably be transferred by positive displacement meteringpumps sized suitably according to the relative proportions of eachstream component. Such metering pumps are manufactured by, for example,Bran+Leubbe. Such metering pumps can be sized and manufactured accordingto requirements thereby enabling precise measuring and metering of theliquids under selective pressure and temperature. The pumps manufacturedby Bran+Leubbe are available from 611 Sugar Creek Boulevard, Delavan,Mich. 53115.

A typical reaction period for bio-diesel produced via the relatively lowpressure method employing sodium hydroxide as the catalyst may be asmuch as 24 hours or more or less. A typical period is greater than 7hours, however, the reaction time for production of bio-diesel as perthe reaction shown in FIG. 8 may be as short as 20 seconds, 30 secondsor 3 minutes or more or less, depending upon the ratio of CO₂ andmethanol and/or ethanol maintained in super-critical phase for theduration of the reaction phase. Typically, the quantity of methanoland/or ethanol blended with sodium hydroxide in a reaction designed toaddress the failure of triglycerides to contact and react with methanolin the most common method employed by industry presently is two timesthe actual quantity of methanol actually required for the reaction.However, in all cases, separation of the resultant blend of liquidmaterials requires either use of a centrifuge or a separation tower orstratification column in which materials separate according to theirspecific gravity. Clearly, by minimizing the quantity of methanol thatexceeds the amount required for a complete reaction is desirable andsuch minimum quantity can be achieved.

Referring again to FIG. 12, an apparatus arranged to maximize efficiencyis shown for materials that comprise L-CO₂ catalyst. Methanol in liquidform can exist at ambient pressure of 14.7 psi and a temperature of 20°C., however, at this temperature and pressure, CO₂ is a gas. In order toprovide super-critical phase methanol and CO₂, the pressure of thecombined materials must exceed 2000 psi when the temperature ismaintained at above 250° C. However, the ratio of methanol to CO₂ isless than 50% methanol and more than 50% CO₂, wherein the CO₂ must be asaturated vapor and/or in super-critical phase at 250° C.

FIGS. 14 and 15 show two views of an enclosed, pressurized hydrocyclonewhich can be constructed to provide yet another aspect of the presentinvention wherein the apparatus can be devised for continuouslyseparating lean beef, beef fat and CO2 from a fluid stream that includesall three components. The enclosed and pressurized hydrocyclonecomprises a uniformly proportioned, centrally disposed enclosure havinga lower segment profile similar to that of a steep inverted cone,typically having a circular profile cross section through the horizontalplane profile, an input port for accepting a fluid stream and at leastthree (desirably at least four) output ports for transferring theseparated components (i.e., beef fat, lean beef and CO2) out of thehydrocyclone. The hydrocyclone effects a density-based separation of thesolid (and liquid) components when suspended in a fluid, wherein such afluid stream entering close to the upper end and at a tangentialorientation relative to the circular cross section of the hydrocyclonebody, thereby accelerating the stream as it descends through thedecreasing diameter (radius) of the steep cone, forcing the heaviercomponents toward the walls of the hydrocyclone and the lightercomponents toward the middle of the enclosed space within thehydrocyclone. Thus, heavier components exit the cyclone through anoutput port at, or toward, the bottom of the hydrocyclone cone shapedsegment, while lighter components exit the hydrocyclone through outputports located at, or toward, the top of the hydrocyclone body. In someembodiments, the fluid stream is pumped into the input port of thehydrocyclone (e.g., using a suitably sized centrifugal pump), which isin communication, via a sealed connection, with a grinder, which isitself in communication, via a sealed connection, with a source of beef,such that a continuous stream of beef is ground prior to entering theinput port. The ground beef is combined with pressurized CO2 to form asuspension of beef particles in the CO2. The suspension may betransferred into input port of the hydrocyclone in a controlled,continuous stream at a velocity and rate of mass flow most suited to thehydrocyclone apparatus. The source of beef is desirably, but notnecessarily, any suitable quantity of 50's, 65's, or even 75's bonelessbeef but most preferably that grade of boneless beef that yields themost lucrative, proportional quantities of fat and lean beef derivedfrom the selected source.

An illustrative embodiment of a hydrocyclone having four output portsand a means for separating lean beef from beef fat using the apparatusis represented in FIG. 14, which represents a three-dimensional view ofthe apparatus, and FIG. 15, which shows a cross-sectional view of theapparatus. As shown in these two figures, the hydrocyclone has a mainbody that includes an upper section 1424 having generally parallel sidewalls and an upper wall 1514, and a lower section 1428, 1534 having agenerally conical longitudinal cross-section. The upper and lowersections may be connected by a continuous annular weld 1426. Thehydrocyclone further includes at least one input port in communicationwith an input conduit 1436 through which a continuous stream of fluidmay enter the upper section of the body of the hydrocyclone. A firstoutput port 1434, 1530 in communication with the lower end of the lowersection of the body is also provided. The first output port may beconnected to the body by a continuous annular weld 1430. Thehydrocyclone includes three additional output ports disposed above theupper section of the body. The second output port 1404, 1562 extendsupwardly from the hydrocyclone and is disposed opposite the first outputport 1432, 1530, such that the first and second output ports share acommon center line. A third output port 1412, 1512 extends upwardly andoutwardly from the top wall 1514 of the upper section of the body of thehydrocyclone. Finally, a fourth output port 1406, 1504 extends outwardlyfrom the centerline of the hydrocyclone and is in communication with thebody of the cyclone through a neck section 1558 connected to the upperwall 1514 of the upper section of the body.

A process for separating the beef fat, lean beef and CO2 from a fluidstream containing beef solids (e.g., boneless, ground beef) suspended influid CO2 may be described as follows. The suspension may be prepared byblending together the ground beef with liquid carbon dioxide pressurizedat least about 480 psia (e.g., 480 psia to about 600 psia) andmaintained at about 34° F. (e.g., about 32° F. to 38° F.) in proportionsof approximately one part ground beef to four or five parts carbondioxide to provide a well formed suspension of solid beef components anda liquid carbon dioxide component. The suspension is continuously pumpedinto input conduit 1436, 1518, as represented by arrows 1401 and 1516.Inside the body of the hydrocyclone, the denser lean beef particles tendto migrate toward the walls of the body of the cyclone, traveling in adownward direction and exiting the hydrocyclone through the first outputport 1432, 1534 in the direction shown by arrows 1434 and 1534. The pathof the lean beef particles is represented by arrows 1522, 1526, 1530,1534, 1550, 1546, 1542, 1540, 1538, 1539, 1536, and 1532. The less densebeef fat particles migrate toward the center of the hydrocyclone,initially in a downward direction, before turning upward, and exitingthrough the third output port 1412, 1512 or the fourth output port 1406,1504. The path of the beef fat particles is represented by arrows 1520,1524, 1528, 1532, 1544, 1548, 1552, 1554, 1503, 1505, 1561 and 1509. TheCO2, being the least dense material, exits at the top of thehydrocyclone through the second output port 1404, 1562 in the directionshown by arrow 1502. The result is a separation of the fluid into threeseparate streams: one comprising predominantly lean beef extracted inthe direction shown by arrow 1434; one comprising predominantly beef fatextracted in the direction shown by arrow 1408; and one comprising CO2represented by arrow 1402.

Beef oil harvested from any suitable ground boneless beef sourcematerial and separated from the components combination of the source,according to any procedure disclosed herein above, can be transferreddirectly to the bio-diesel production processing system.

For the purposes of this disclosure and unless otherwise specified, “a”or “an” means “one or more”. All patents, applications, references andpublications cited herein are incorporated by reference in theirentirety to the same extent as if they were individually incorporated byreference.

As will be understood by one skilled in the art, for any and allpurposes, particularly in terms of providing a written description, allranges disclosed herein also encompass any and all possible subrangesand combinations of subranges thereof. Any listed range can be easilyrecognized as sufficiently describing and enabling the same range beingbroken down into at least equal halves, thirds, quarters, fifths,tenths, etc. As a non-limiting example, each range discussed herein canbe readily broken down into a lower third, middle third and upper third,etc. As will also be understood by one skilled in the art all languagesuch as “up to,” “at least,” “greater than,” “less than,” and the likeinclude the number recited and refer to ranges which can be subsequentlybroken down into subranges as discussed above. Finally, as will beunderstood by one skilled in the art, a range includes each individualmember.

While the preferred embodiment of the invention has been illustrated anddescribed, it will be appreciated that various changes can be madetherein without departing from the spirit and scope of the invention.

1. A method of continuously producing bio-diesel by atransesterification of animal-derived triglycerides, the methodcomprising reacting a first stream comprising the triglycerides with asecond stream comprising ethanol, methanol, or a combination thereof inthe presence of fluid CO₂ within a pressurized conduit for a period oftime sufficient to produce bio-diesel and glycerol at a pressure of atleast 1000 psia and a temperature of at least 80° F.
 2. The method ofclaim 1, wherein the first stream and the second stream are combined inproportionally controlled mass flow rates within the pressurized conduitto provide a pressurized third stream, and further wherein the firststream, the second stream, or both the first and second streams comprisethe fluid CO₂.
 3. The method of claim 2, wherein the first streamcomprises the fluid CO₂.
 4. The method of claim 2, wherein the secondstream comprises supercritical ethanol, supercritical methanol,supercritical CO₂, or a combination thereof.
 5. The method of claim 2,wherein the second stream is divided into two sections, and furtherwherein the first stream is sandwiched between two sections of thesecond stream.
 6. The method of claim 1, wherein the triglycerides arederived from beef fat.
 7. The method of claim 1, wherein the conduit hasan internal cross-sectional diameter of about 100-200 microns.
 8. Themethod of claim 1, wherein the conduit has an entry end having acircular cross-sectional profile and a low profile section having anelongated cross-sectional profile.
 9. The method of claim 2, wherein thefirst stream and the second stream flow at substantially equal velocity.10. The method of claim 1, wherein the reaction extends for a period ofno more than about 1 minute.
 11. The method of claim 1, wherein thereaction extends for a period of no more than about 20 seconds.
 12. Themethod of claim 1, wherein the reaction occurs at a temperature of about200-350° C. and a pressure of about 2000-3000 psi.
 13. The method ofclaim 1, wherein the ethanol or methanol is present in excess.
 14. Themethod of claim 1, further comprising separating the bio-diesel from theglycerol.
 15. The method of claim 14, wherein the step of separating thebio-diesel from the glycerol is carried out continuously in a streamtransferred via an hydrocyclone.
 16. The method of claim 14, wherein thestep of separating the bio-diesel from the glycerol is carried out in acentrifuge.
 17. The method of claim 14, further comprising the step ofseparating the residual fluid CO₂ from the bio-diesel to providesubstantially pure, contaminant free bio-diesel.
 18. The method of claim14, further comprising filtering the separated bio-diesel.
 19. Themethod of claim 18, further comprising blending the filtered bio-dieselwith fossil fuel derived diesel.
 20. The method of claim 2, wherein themass flow of the first stream is proportional to the mass flow of thesecond stream.
 21. An apparatus for combining fluids comprising: (a) afirst drive shaft capable of rotating, the first drive shaft defining afirst central conduit in communication with one or more aperturesrunning perpendicular to the central conduit; (b) a first disc fixedaround one end of the first drive shaft, the first disc having a planarsurface and radial ridges extending along the planar surface; (c) asecond drive shaft capable of rotating, the second drive shaft defininga second central conduit in communication with one or more aperturesrunning perpendicular to the central conduit; (d) a second disc fixedaround one end of the second drive shaft and mounted in parallel,contacting proximity with the first disc such that an annular space isformed between the first and second discs, wherein the one or moreapertures of the first drive shaft and the one or more apertures of thesecond drive shaft open into the annular space between the first andsecond discs and further wherein the radial ridges of the first discdefine radial slots between the planar surface of the first disc and thecontacting surface of the second disc; and (e) an enclosing coverenclosing the space around the first and second discs and defining aconduit for transferring fluids out of the enclosed space.
 22. Theapparatus of claim 21, wherein the radial slots have a height of lessthan 200 microns.
 23. The apparatus of claim 21, further comprising adiffusing disc extending over the one or more apertures of the firstdrive shaft and the one or more apertures of the second drive shaft. 24.A method for continuously producing bio-diesel using the apparatus ofclaim 21, the method comprising rotating the first and second discs inopposite directions, transferring a first stream comprisingtriglycerides through at least one of the first or second centralconduits, and transferring a second stream comprising ethanol, methanol,or a combination thereof through at least one of the first and secondcentral conduits, whereby the streams contact and react to formbio-diesel and glycerol in the annular space between the first andsecond discs.
 25. The method of claim 24, wherein the first stream, thesecond stream, or both streams further comprise liquid or supercriticalCO₂, and further wherein the second stream comprises supercriticalethanol, methanol or a combination thereof.
 26. An apparatus for mixingfluids comprising: (a) an inner concentric member comprising: (i) afirst conduit wall defining a first centrally disposed conduit and afirst flange having a substantially flat face disposed around the firstconduit; and (ii) a second conduit wall defining an annular secondcentrally disposed conduit and a second flange having a substantiallyflat face disposed around the second conduit, wherein the second flangeis disposed in diametric opposition to the first flange, such that thefirst and second conduits share a common center line and an annularspace is formed between the substantially flat faces of the first andsecond flanges; (b) an outer concentric member concentrically enclosingthe inner concentric member comprising: (i) a third conduit walldisposed around and concentric with the first conduit wall, such thatthe space between the third conduit wall and the first conduit wallforms a third conduit, and a third flange having a substantially flatface disposed around the third conduit and concentric with the firstflange; and (ii) a fourth conduit wall disposed around and concentricwith the second conduit wall, such that the space between the fourthconduit wall and the second conduit wall forms a fourth conduit, and afourth flange having a substantially flat face disposed around thefourth conduit and concentric with the second flange, wherein the fourthflange is disposed in diametric opposition to the second flange, suchthat the third and fourth conduits share a common center line and anannular space is formed between the substantially flat faces of thethird and fourth flanges; and (c) an outer housing concentricallyenclosing the outer concentric member.
 27. The apparatus of claim 26,wherein the substantially flat face of the first flange, the thirdflange, or both, comprises radial ridges and further wherein the radialridges define radial slots between the first flange and the secondflange, between the third flange and the fourth flange, or both, andfurther wherein the radial slots have a height of no more than about 200microns and a width of no more than about 200 microns.
 28. A method forcontinuously producing bio-diesel using the apparatus of claim 26, themethod comprising rotating the first and second flanges in oppositedirections, rotating the third and fourth flanges in oppositedirections, transferring a first stream comprising triglycerides throughat least one of the first and second central conduits, and transferringa second stream comprising ethanol, methanol or a combination thereforethrough at least one of the third and fourth conduits, whereby thestreams contact and react to form bio-diesel and glycerol in the annularspace between the third and fourth flanges.
 29. The method of claim 28,wherein the first stream, the second stream, or both streams furthercomprise fluid CO₂.
 30. An apparatus for mixing fluids comprising: (a)an inner concentric member comprising: (i) a first shaft and a firstflange having a substantially flat face disposed around the first shaft;and (ii) a second shaft and a second flange having a substantially flatface disposed around the second shaft, wherein the second flange isdisposed in diametric opposition to the first flange, such that thefirst and second shafts share a common center line and an annular spaceis formed between the substantially flat faces of the first and secondflanges; (b) an outer concentric member arranged concentrically aroundthe inner concentric member comprising: (i) a first conduit walldisposed around and concentric with the first shaft, such that the spacebetween the first conduit wall and the first shaft forms a firstconduit, and a third flange having a substantially flat face disposedaround the first conduit and concentric with the first flange, whereinthe substantially flat face defines a plurality of tapered recessesextending in a radial direction such that a cross section perpendicularto the center line of said tapered recesses defines a portion of acircle; and (ii) a second conduit wall disposed around and concentricwith the second shaft, such that the space between the second conduitwall and the second shaft forms a second conduit, and a fourth flangehaving a substantially flat face disposed around the second conduit andconcentric with the second flange, wherein the fourth flange is disposedin diametric opposition to the third flange, such that the first andsecond conduits share a common center line and an annular space isformed between the substantially flat faces of the third and fourthflanges; (iii) a plurality of tapered rollers retained in the pluralityof tapered recesses defined by the third flange and held against thesubstantially flat face of the fourth flange, such that the centerlineof each tapered roller converges at the center of the annular spacebetween the first and second flanges; and (c) an outer housing enclosingthe outer concentric member.
 31. A method for continuously producingbio-diesel using the apparatus of claim 30, the method comprisingrotating the third and fourth flanges in opposite directions,transferring a first stream comprising triglycerides through at leastone of the first and second conduits, and transferring a second streamcomprising ethanol, methanol or a combination therefore through at leastone of the first and second conduits, whereby the streams aretransferred to spaces around the tapered rollers where they arecompressed to generate sufficient heat and pressure to producesupercritical conditions under which the triglycerides and ethanol,methanol or combination thereof react to form bio-diesel and glycerol